X043748

TM 11-6140-203-14-3
TECHNICAL MANUAL
OPERATOR'S, ORGANIZATIONAL DIRECT SUPPORT,

AND GENERAL SUPPORT MAINTENANCE MANUAL
NONAIRCRAFT NICKEL CADMIUM BATTERIES
HEADQUARTERS, DEPARTMENT OF THE ARMY
7 NOVEMBER 1979
TM 11-6140-203-14-3
WARNINGS
DANGEROUS CHEMICALS ARE USED IN NICKEL-CADMIUM
BATTERIES
The electrolyte used in nickel-cadmium batteries contains potassium hydroxide

(KOH), which is a caustic chemical agent. Serious and deep burns of body tissue
will result if the electrolyte comes in contact with the eyes or any part of the body.
Use rubber gloves, rubber apron, and protective goggles when handling the
electrolyte. If accidental contact with the electrolyte is made, use ONLY clean
water and immediately (seconds count) flush contaminated areas. Continue
flushing tenth large quantities of clean water. Seek medical attention without delay
for eyes.
EXPLOSIVE GASES ARE GENERATED BY NICKEL CADMIUM BATTERIES
Hydrogen and oxygen gases are generated in explosive proportion while the
nickel-cadmium battery is being charged. Charge the nickel-cadmium battery in a
well-ventilated area to reduce concentrations of explosive gases. Turn off the
battery charger before connecting or disconnecting the nickel-cadmium battery to
prevent arcing. Do not use matches or an open flame in the charging area. Arcs,
flames, or sparks in the charging area will ignite the gases and cause an explosion.
The battery box cover must be removed and the battery case vent plug (if used)
must be open when charging.
DO NOT MIX SULPHURIC ACID AND KOH
The electrolyte used in nickel-cadmium batteries reacts violently to the sulfuric

acid used in the more common lead-acid types of batteries. DO NOT add sulfuric
acid electrolyte to the battery; the mixing of the acid and KOH electrolytes will
cause a violent reaction which could result in the splattering of the mixture into the
eyes and onto the skin. Every effort must be made to keep nickel cadmium
batteries as far away as possible from lead-acid batteries. Do not use the same
tools and materials such as screwdrivers, wrenches, syringes, hydrometers, and
gloves for both types of batteries. Any trace of acid or acid fumes will permanently
damage nickel-cadmium batteries on contact.
a
TM 11-6140-203-14-3
WARNINGS
BATTERY SHOP SAFETY PRACTICES
Nickel-cadmium battery maintenance personnel should be thoroughly trained in the

use of charging, discharging, and test procedures. The employment of properly
trained personnel in the maintenance of nickel-cadmium batteries cannot be
overemphasized. The nickel-cadmium battery shop must be used ONLY to
maintain nickel-cadmium batteries. Anything associated with lead-acid batteries
should never come in contact with nickel-cadmium batteries, including acid fumes.
In addition to the equipment required to maintain nickel-cadmium batteries; the
nickel-cadmium battery shop should have adequate ventilation; deluge shower,
eyewash fountain, and fire extinguisher (CO2).
TIGHTENING TERMINAL SCREWS AND STUDS
Be extremely careful when tightening terminal screws and studs. Bodily injury and
damage to the equipment may result if the torque wrench accidentally causes a
short circuit.
FIRE FIGHTING SAFETY PRACTICE
CO2 is an acceptable fire extinguishing agent once a fire has developed. In no

case should CO2 be directed into a battery compartment to effect cooling or
displace explosive gases. The static electricity generated by the discharge of the
extinguishers could explode hydrogen/oxygen gases trapped in the battery
compartment.
c
TM 11-6140-203-14-3
TECHNICAL MANUAL HEADQUARTERS

DEPARTMENT OF THE ARMY
NO. 11-6140-203-14-3 WASHINGTON, DC, 7 November 1979
OPERATOR'S, ORGANIZATIONAL, DIRECT SUPPORT, AND

GENERAL SUPPORT MAINTENANCE MANUAL
NONAIRCRAFT NICKEL-CADMIUM BATTERIES
REPORTING OF ERRORS
You can improve this manual by recommending improvements using DA

Form 2028-2 located at the back of the manual. Simply tear out the self-
addressed form, fill it out as shown on the sample, fold it where shorn, and drop it
in the mail.
If there are no blank DA Forms 2028-2 in the back of the manual, use the
standard DA Form 2028 (Recommended Changes to Publications and Blank
Forms) and forward to Commander, US Army Communications and Electronics
Materiel Readiness Command, ATTN: DRSEL-ME-MQ, Fort Monmouth, NJ 07703.
In either case, a reply will be furnished direct to you.
Paragraph Page
CHAPTER 1. INTRODUCTION ............................................................................... 1-1 1-1
2. SPECIFIC DATA FOR EACH INDIVIDUAL BATTERY TYPE
Section I. Battery, Storage BB-422/U ................................................................. 2-1 2-1
II. Battery, Storage BB-429/U ................................................................. 2-4 2-2
III. Battery, Storage BB-501/U ................................................................. 2-7 2-5
IV. Battery, Storage BB-651/U ................................................................. 2-9 2-7
VI. Battery, Storage BB-672/U ................................................................. 2-12 2-8
VIII. Battery, Storage BB-693A/U .............................................................. 2-15 2-10
IX. Battery, Storage BB-634/U (6TNC) .................................................... 2-18 2-13
CHAPTER 3. INSTALLATION ................................................................................. 3-1 3-1
4. ORGANIZATIONAL MAINTENANCE.................................................. 4-1 4-1
5. DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE....... 5-1 5-1
APPENDIX A. REFERENCES.......................................................................................................... A-1
B. COMPONENTS OF END ITEM LIST (Not applicable)
C. ADDITIONAL AUTHORIZATION LIST (Not applicable)
D. MAINTENANCE ALLOCATION
Section I. Introduction............................................................................................................. D-1
II. Maintenance Allocation Chart.................................................................................. D-3
III. Tool and Test Equipment Requirements.................................................................. D-9
IV. Remarks ................................................................................................................. D-10
APPENDIX E. EXPENDABLE SUPPLIES AND MATERIALS LIST
Section I. Introduction............................................................................................................. E-1
II. Expendable Supplies and Materials List .................................................................. E-3
INDEX ........................................................................................................................................................ Index-1
LIST OF ILLUSTRATIONS
Title
Number Title Page
2-1 Battery, Storage BB-422/U, Cover Removed ....................................................................... 2-0

2-2 Battery, Storage BB-431/U (Cell), Parts Location ................................................................ 2-1
2-3 Battery, Storage BB-422/U, Cell Layout ............................................................................. 2-2
2-4 Battery, Storage BB-429/U, Cover Removed ...................................................................... 2-3
2-5 Battery, Storage BB-429/U, Parts Location ......................................................................... 2-4
2-6 Battery, Storage BB-429/U, Cell Layout ............................................................................. 2-5
2-7 Battery, Storage BB-501/U, Exploded View ......................................................................... 2-6
2-8 Battery, Storage BB-651/U, Exploded View ......................................................................... 2-8
2-9 Battery, Storage BB-672/U, Cover Removed ...................................................................... 2-9
2-10 Battery, Storage BB-693A/U (Manufactured by Marathon (Sonotone) Battery Corporation),
Parts Location ................................................................................................................... 2-11
2-11 Battery, Storage BB-693A/U (Manufactured by General Electric), Parts Location................. 2-12
2-12 Battery, Storage 634/U (6TNC), Cover Removed ................................................................ 2-15
*This manual supersedes TM 11-6140-203-15-3, 1 December 1969, including all changed

i
TM 11-6140-203-14-3
Number Title Page
3-1 Typical Nickel-Cadmium Battery Packaging (Multiples) ................................ ....................... 3-2

5-1 Capacity Test Connection Diagram ................................ ................................ .................... 5-3
5-2 Electrolyte Level Adjustment................................ ................................ ............................... 5-5
5-3 Discharging Correction Diagram ................................ ................................ ......................... 5-6
5-4 Discharging Battery, Storage BB-422/U, Using Discharge Fixture ................................ ....... 5-7
5-5 Cell Puller................................ ................................ ................................ ........................... 5-10
5-6 Fabrication Diagram for Metal Vent Valve Tester................................ ................................ . 5-13
5-7 Fabrication Diagnose for Fillercap Vent Valve Tester ................................ .......................... 5-14
ii
TM 11-6140-203-14-3
CHAPTER 1
INTRODUCTION
1-1. Scope
a. This manual is one of the series of three and it covers the specific data and maintenance allocation
for each nonaircraft nickel-cadmium battery. Refer to TM 11-6140-203-15-1, for general information pertaining
to the description, functioning, operation, and maintenance of nickel-cadmium batteries. Refer to TM 1 11-
6140-203-14-2 for the specific data and maintenance allocation for each aircraft nickel-cadmium battery.
b. TM 11-6140-203-20P-3 and TM 11-6140203-34P-3 contain the repair parts and special tools lists
for nonaircraft nickel-cadmium batteries.
c. Appendix D is current as of 8 November 1978.
1-2. Indexes of Publications
a. DA Pam 310-4. Refer to the latest issue of DA Pam 310-4 to determine whether there are new
editions, changes, or additional publications pertaining to the equipment.
b. DA Pam 310-7. Refer to DA Pam 310-7 to determine whether there are modification work orders
(MWO's) pertaining to the equipment.
1-3. Forms and Records
a. Reports of Maintenance and Unsatisfactory Equipment. Maintenance forms, records, and reports
which are to be used by maintenance personnel at all maintenance levels are listed and prescribed by TM 38-
750.
b. Report of Packaging and Handling Deficiencies. Fill out and forward DO Form 6 (Packaging
Improvement Report) as prescribed in AR 700-58/NAVSUPINST 4030.29/AFR 71-13/MCO P4030.29A, and
DLAR 4145.8.
c. Discrepancy in Shipment Report (DISREPJ (SF 361). Fill out and forward Discrepancy in Shipment
Report (DISREP) (SF 361) as prescribed in AR 55-38/NAVSUPINST 4610.33B/AFR 75-18/MCO P4610.19C
and DLAR 4500.15.
1-4. Administrative Storage
A nonaircraft nickel-cadmium battery can be placed in administrative storage because of no immediate
operational need and the necessity to reduce the maintenance workload; or to hold it ready while the associated
end item of equipment is in the repair or overhaul process. The nickel-cadmium battery is handled differently
under each set of circumstances.
a. Normal Administrative Storage Procedures. The following procedure applies when a nickel-
cadmium battery is being placed in normal administrative storage.
(1) Remove the nickel-cadmium battery from the end item of equipment.
(2) Perform the cleaning procedures in paragraph 4-7.
(3) Place the nickel-cadmium battery in the administrative storage area making sure that the
connector terminals are not accidentally short circuited. It is not necessary to discharge the nickel-cadmium
battery since the charge will be lost through normal leakage and it will be deep-cycle discharged and recharged
prior to returning to service. Protect from freezing and excessive heat.
(4) When the nickel-cadmium battery is to be returned to service, perform the full quarterly or
every 100 cycles service procedure contained in paragraph 5-7.
b. Hold-Ready Administrative Storage Procedures. The following procedure applies when a nickel-
cadmium battery is placed in a hold-ready administrative storage while the end item of equipment is in the
repair or overhaul process.
(1) Remove the nickel-cadmium battery from the equipment.
(2) Perform those quarterly or every 100-cycle service procedures contained in paragraph 5-7
which service and deep-cycle discharge the nickel-cadmium battery. Leave the shorting device connected
across the terminals of each cell.
(3) Place the nickel-cadmium battery in the ready hold administrative storage area. Protect from
freezing and excessive heat.
(4) When the nickel-cadmium battery is required for installation in the repaired or overhauled
end item of equipment, remove it from administrative storage. Remove the shorting device from across the
terminals of each cell.
(5) Charge the nickel-cadmium battery in accordance with the instructions contained in
paragraph 5-5.
(6) Install the nickel-cadmium battery in the end item equipment.
1-5. Destruction of Army Electronics Materiel
Destruction of Army electronics materiel to prevent enemy use shall be in accordance with TM 750-244-2.
1-6. Reporting Equipment Improvement Recommendations
EIR's will be prepared using Standard Form 368. Instructions for preparing EIR's are provided in TM 38-750.
EIR's should be mailed direct to Commander, US Army Communications and Electronics Materiel Readiness
Command, AMEN: DRSEL-ME MQ, Fort Monmouth, NJ 07703. A reply will be furnished direct to you.
1-1
TM 11-6140-203-14-3
Figure 2-1. Battery, Storage B-422/U Cover Removed.
2-0
TM 11-6140-203-14-3
CHAPTER 2
SPECIFIC DATA FOR EACH INDIVIDUAL BATTERY TYPE
SECTION I. BATTERY STORAGE BB-422/U
2-1. Tabulated Data for BB-422/U (fig. 2-1)
Type ................................ .......... Nickel cadmium (vented). Negative (charged) ................ Cadmium.
Number of Cells......................... 19. Separator material................. Plastic laminate.
Type of cell................................ B8431/U. Cell case material Molded nylon or
Electrolyte ................................ . Potassium hydroxide (KOH), 31 Acrylonitile,
percent (by weight) in distilled Butediene-
water. Styrene (ABS).
Operating- Range:
Temperature ....................... -40°C F. (-40°C.) to 125°F. 2-2. Weight and Dimensions of BB-422/U
(51.7°C.). Battery, Storage BB-422/U (NSN 6140-00-789-
2118) weighs 32 pounds. The battery is
Atmospheric pressure ......... Sea level to 10,000 feet (20.6 711/32 inches high, 53/4 inches wide and
inches of mercury 0.1). 12Yt6 inches deep. Refer to figure 2-1 for BB-
Storage: 422/U parts location.
Duration.............................. Unlimited, regardless of state of
charge. 2-3. Physical Characteristics of BB-431/U
Temperature ............................. ..-65°F. (-53.9°C.) to 165°F. (Cell)
(73.9°C.). The overall dimensions of Battery, Storage
Atmospheric pressure ................ Sea level to 50,000 feet 3.4 BB-431/U (cell) (NSN 6140-00-014-6583) are
inches 661/64 inches high, 27/" inches wide, 15/64
of mercury 0.1). inches deep, and it weighs 11/2s pounds.
Electrical Data: Refer to figures 2-2,and 2-3 for parts location
Rating................................ . 14 ampere-hous. and cell layout for the BB-422/U.
Current at rated load (2.8
amperes):
Temperatures between 0. F.
(-17.8°C.), and 125°F.
(51.7°C.) ............................ 2.8 amperes for approximately 5
hours.
Temperatures between 0°F.

(-17.8°C.), and -40°F.
(-40°C.).............................. 2.8 amperes for approximately 3
hous.
Voltage:
Open circuit ........................ .Approximately 25 volts (fully
charged, with a 24-hour rest
period).
Under rated load (2.8 amperes):

Temperatures between 75°
F. (23.9°C.) and 84°F.
(28.9°C.) ............................ 22 volts for approximately 5
hous.
Temperatures between 0°F.

(-17.8°C.) and -40°F.
(-40°C.).............................. 22 volts for approximately 3
hours.
Battery terminal links: Figure 2-2. Battery, Storage BB-431/U (Cell),
Material ............................. Nickel-plated copper. Parts Location.
Number .............................. 18.
Cell plate materials:
Positive............................... Nickel Oxide
2-1
TM 11-6140-203-14-3
Figure 2-3. Battery, Storage BB-422/U, Cell Layout
SECTION II. BATTERY, STORAGE BB-429/U
2-4. Tabulated Data for BB-429/U (fig. 2-4) Temperatures between 0°F.
Type ................................ Nickel-cadmium (vented). (-17.8°C.) and -40°F.
Number of cells ............... 5 (40°C.) ..................... 2.8amperesfor approximately
3 hours.
Type of cell...................... B418/U
Electrolyte ....................... Potassium hydroxide (KOH), 31 Under rated load (2.8 amperes):
percent (by weight) in distilled Temperatures between 75°
water. F. (25°C.) and 85°F.
Operating range:.............. (29.4°C.)................... 6.0 volts for approximately 5
Temperature ............. -65°F. (-53.9°C.) to 125°F. hours.
(51.70 C.). Temperatures between 0°F.
Atmospheric pressure ....Sea level to 10,000 feet (20.6 (-17°C.) and -40°F.
inches of mercury 0.1). (-40°C.) .................... 5.7 volts for approximately 3
Storage: hours.
Duration.................... Unlimited, regardless of state of Intercell connector:
................................ . charge. Material .................... Nickel-Plated copper.
Temperature ............ -65°F (53.9°C.) to 165°F Number ..................... 4.
(73.9°C.). Cell plate materials:
Atmospheric pressure ....Sea level to 50,000feet (3.4 Positive (charged)......Nickel oxide.
inches of mercury 0.1). Negative (charged) ....Cadmium.
Electrical data:................. Separator material ...........Plastic laminated.
Rating ...................... 14 ampere-hours. Cell case material............. Mold nylon or Acrylonitrile-
Butadiene-Styrene.
Current at rated load (2.8 am-
peres): Voltage:
Temperatures between 0 F. Open circuit ............... Approximately 6.5 volts (fully
(-17.8°C.) and between charged, with a 24-hour
125°F. (51.7°C.)...... 2.8 amperes for approximately 5 rest period).
hours.
2-2
TM 11-6140-203-14-3
Figure 2-4. Battery, Storage BB-429/U, Cover Removed.
2-5. Weight and Dimensions of BB-429/U
Battery, Storage BB-429/U (NSN 6140-00-996-3746) weighs approximately 7 pounds. The battery is 61/4
inches high, 229/64 inches wide, and 73/64 inches deep. Refer to figure 2-5 for BB-429/U parts location.
2-6. Physical Characteristics of BB-418/U (Cell)
The overall dimensions of Battery, Storage BB-418/U (cell) (NSN 6140-00-855-7634) are 53/4 inches high, 21/4
inches wide, and 1 inch deep, and it weighs 11/8 pound. Refer to figures 2-5 and 2-6 for BB-418/U parts
location and BB-429/U cell layout respectively.
2-3
TM 11-6140-203-14-3
Figure 2-5. Battery, Storage BB-429/U, Parts Location.
2-4
TM 11-6140-203-14-3
EL4EC006
Figure 2-6. Battery, Storage BB-429/U, Cell Layout
SECTION III. BATTERY, STORAAGE BB-501/U
2-7. Tabulated Data for BB-501/U (fig. 2-7)

Type ................................ Nickel-cadmium (vented). Approximately 0 F.
Number of cells ............... 20 (-17.8 C.) ........................ 12.6 ampere-hours at 24
Nomenclature of cell........ Battery, Storage BB-613/U volts or 25.2 ampere
Electrolyte ....................... Potassium hydroxide (KOH) 31 hours at 12 volts
percent (by weight( in distilled Approximately -40 F.
water. (-40 C) ............................ 8.4 ampere hours at 24 volts
or 16.8 ampere-hours at
12 volts.
Operating Range: Current:
Temperature ............. -40 F.(-40 C.) to 165 F. At temperature of:
(75.0 C.) Approximately 75 F.
Atmospheric Pressure .... Sea level to 10,000 feet 20.6 (23.9 C.).......................... 2.8 amperes at 24 volts for 5
inches of mercury +/-0.1) hours or 5.6 amperes at
Storage: 12 volts for 5 hours.
Duration.................... Unlimited, regardless of state of Approximately -40 F
charge (-40 C) ............................ 2.8 amperes at 23 volts for 3
Temperature ............. -80 F. (-62 C.) to 165 F. hours or 5.6 amperes at
(75 C.) 11.5 volts for 3 hours.
Atmospheric Pressure......Sea level to 50,000 feet (3.4 Voltage Open Circuit ........Approximately 13 volts or 26
inches of mercury+/-0.1). volts (dependent upon
cable assembly used and
Electrical Data: a fully charged battery
Rated 5-hour discharge with a 24 hour rest period)
capacity at temperature of :
Approximately 75 F.
(23.9 C.) ......................... 14.0 ampere-hours at 24 volts or Minimum Cycle Life (charge and
discharge) ................. 1,500 cycles
2-5
TM 11-6140-203-14-3
Figure 2-7. Battery, Storage BB-501/U, Exploded View
2-6
TM 11-6140-203-14-3
Battery, Storage BB-50I/U (NSN 6140-00-134-0850) weighs approximately 32.5 pounds. The battery is 7 3/16
inches long, 6 3/4 inches wide and 7/16 inches high. Refer to figure 2-7 for parts location and BB-613/U (cell)
layout. The BB-613/U (cell) (NSN 6140-00-134-0849) is 5 3/4 inches high, 2¼ inches wide, and 1 inch deep and
weighs 1 1/8 pound.
SECTION IV. BATTERY, STORAGE BB-651/U
2-9. Tabulated Data For BB-651/U (fig. 2-8) Temperatures between

Type ................................ Nickel-cadmium. 0°F. (-17.8°C.) and
Number of cells ............... 20 (four 5-cell monoblocks). -40°F. (-40°C.) .........1.1amperes for approximately 3
Type of cell ..................... BB-547/U (5 cell monoblock). hours.
Electrolyte ...................... Potassium hydroxide (KOH), 31 Voltage:
percent (by weight) in distilled Open circuit .............. Approximately 26 volts(battery
water. fully charged, with a 24-hour
Operating Range: rest period).
Temperature ............. -40°F. (-40°C.) to 125°F. At rated load of 1.1 amperes:
(51.7°C.). Temperatures between
Atmospheric pressure..... Sea level of 10,000 feet (20.6 75°F. (23.9°C.) and
inches of mercury 0.1 inch). 85°F. (29.4°C.) ........24 volts for approximately 5
Storage: hours.
Duration ................... Unlimited, regardless of state of Temperatures between
charge. 0°F. (-17.8°C.) and
Temperature.................... -65°F. (-53.9°C.) to 165°F. -40°F. (-40°C.) .........23 volts for approximately 3
(73.90 C.). hours.
Atmospheric pressure..... Sea level to 50,000 feet (3.4 inch Intercell connector:
of mercury 0.1 inch). Material ..................... Nickel.
Electrical Data: ................ Quantity ................... 18.
Rating ..................... 5.5 ampere-hours. Cell plate materials:
Current at rated load of 1.1 Positive plate (charged)..Nickel oxide.
amperes: Negative plate (caged) ......Cadmium.
Temperatures between Separator material.............Nylon cellophane sandwich.
0 F. (-17.8°C.) and Monoblock case materials....Acrylonitrile-Butadiene-Styrene
125 F. (51.70 C.) 1.1 ampere for approximately 5 (ABS).
hours.
2-7
TM 11-6140-203-14-3
Figure 2-8. Battery, Storage BB-651/U, Exploded View
Battery, Storage BB-651/U (NSN 6140-01-037-7344) weighs approximately 12 pounds. The battery is 4 3/4
inches high, 4 1/8 inches wide, and 13 inches deep. Refer to figure 2-8 for BB651/U parts location.
2-11. Physical Characteristics of BB-547/UMonoblock Cell
The overall dimensions of the five cell monoblock (NSN 6140-01-037-7343) are 3 11/16 inches high, 2 1/2
inches wide, and 3 9/16 inches deep. Refer to figure 2-8 for monoblock parts location and cell layout for the
BB-651/U.
SECTION VI. BATTERY, STORAGE BB-672/U
2-12. Tabulated Data For BB-672/U Storage:

Type ................................ Nickel- cadmium(vented) Duation...................... Unlimited, regardless of state of
Number of cells .............. 5 BB671/U. charge
Type of cell...................... Potassium hydroxide (KOH), 31 Temperature.............. -65 F. (-53.9 C.) to 165 F.
percent (by weight) in distilled (73.9 C.).
water. Atmosphere c pressure.....Sea level . to 50,000 . feet (3.4
inches of mercury 0.1).
Operating range: Electric Data:
Temperature ............. -40 F. (-40°C.) to 125 F. Rating ....................... 4.7ampere-hours.
(51.7 C.). Current at rated load (0.94
Atmospheric Pressure Sea level to 10,000 feet (20.6 ampere):
inches of mercury 0.1). Temperatures between
2-8
TM 11-6140-203-14-3
0°F. (17.8°C.) and ... 850 F. (29.40 C.) .......6.0 volts for approximately 5
125°F. (51.7°C.)...... 0.94 ampere for approximately 5 hours.
hours. Temperatures between
Temperatures between 0°F. (-17.8°C.) and
0°F. (-17.80 C.) and -40°F. (-40°C.) .........5.75 volts for approximately 3
-40- F. (-400 C.).. 0.94 ampere for approximately 3 hours.
hours. Intercell connector:
Voltage: Material ..................... Nickel-Plated copper.
Open circuit .............. Approximately 6.5 volts (fully Number ..................... 4.
charged, with a 24-hour rest Cell plate materials:
period). Positive (charged) ............ Nickel oxide.
Under rated load (0.94 am- Negative (charged) ...........Cadmium.
pere) Separator material ...........Nylon cellophane sandwich or
Temperatures between double felted nylon.
75°F. (23.9°C.) and Cell Use Material ............. Nylon.
Figure 2-9. Battery, Storage BB-672/U, Cover Removed.
2-9
TM 11-6140-203-14-3
2-13. Weight and Dimensions

Battery, Storage BB-672/U (NSN 6140-00-777-3322) weighs approximately 2 pounds. The battery is 4 1/64
inches high, 2 13/32 inches wide, and 3 1/4 inches deep. Refer to figure 2-9 for a physical layout of the battery.
No repair parts are authorized.
2-14. Physical Characteristics of BB-671/U (Cell)

The overall dimensions of Battery, Storage BB-671/U (cell) (NSN 6140-00-764-1624) are 4 1/16 inches high, 2
9/64 inches wide, 2 1/32 inch deep, and weighs approximately 6 3/10 ounces. Refer to figure 2-9 for cell layout
of the BB-672/U
SECTION VII. BATTERY, STORAGE BB-693A/U
2-15 Tabulated data for BB-693A/U charged with 24-hour rest

Type ................................ Nickel-cadmium (vented). period).
Number of cells ............... 19 BB-60cA/A. Open circuit at J1 ......Approximately 9 volts (fully
Electrolyte ....................... Potassium hydroxide (KOH), 31 charged with 24-hourrest
percent (by weight) in distilled period).
water. Under load at J2:
Operating range:.............. Temperature of approx-
Temperature ............. -40°F. (-40°C.) to 125°F. imately 750 F. (23.9°C.):
(51.7°C.). 8-ampere load ...........24 volts decreasing to not less
Atmospheric pressure Sea level to 100,000 feet (0.4 inch than 19.2 volts in 5 hours.
of mercury). 30-ampere load ........24 volts decreasing not less
Storage: than 18 volts in 1 hour.
Duration.................... Unlimited, regardless of state of 270-ampere load .......24 volts decreasing to not less
charge than 14.4 volts in 5 minutes.
Temperature ............. -65°F. to 165° F. (73.9°C.). 772-ampere load .......24 volts decreasing to not
less
Atmospheric pressure ....Sea level to 100,000 feet (0.4 inch than 11.0 volts in I minute (3,
of mercury). 20 second pulses).
Electrical Temperature of approx-
Rating....................... 30 ampere hours at I hour rate, Imltel -22°F. (-30°
40 ampere-hours at 5 hours C):
rate. 270-ampere load ......24 volts decreasing to not less
Current: ........................... than 14.4 volts in 3 minutes.
At temperature of ...... Battery terminal links:
approximately 75°F.. Material ..................... Nickel-plated copper.
(23.90 C.) ........................ 8 amperes for approximately 5 Number ..................... 19.
hours; 30 amperes for approx- Cell plate materials:
imatey 1 hour, 270 amperes Positive (charged)......Nickel oxide.
for approximately 5 minutes. Negative (charged) ....Cadmium.
At temperature of Separator material............ Plastic laminate.
approximately -22°F. Cell case material............. Molded Nylon.
(30°C.)..................... 270 amperes for approximately 3 Connector type (24-vol) ....Elcon (16163-7) (12).
minutes Connector type (8.4-volt) ..MS3102R-16-12S (11).
Voltage: Connector type Near) .......M3102R-14A-7P (3).
Open circuit at J2...... Approximately 25 volts (fully
2-10
TM 11-6140-203-14-3
Figure 2-10. Battery, Storage BB-693A/u (Manufactured by Marathon (Sonotone) Battery Corporation), Parts Location.
1. BB-693A/U (Marathon) 11. Lockwasher 21. Thermostat 31. Hexagonal head screw
2. Case Assembly 12. Phillip’s-head screw 22. Thermostat 32. shim
3. Connector receptacle J1 13. Rectangular ring 1A1 23. Phillip’s-head screw 33. Shim
4. Connector receptacle J3 14. Pressure relief valve 24. Battery terminal link 34. Manual Vent valves.
5. Connector receptacle J2 15. Threaded cap 25. Battery terminal link
6. O-ring 16. Lined Cover 26. Battery terminal link
7. O-ring 17. Cable assembly 27. Battery terminal link
8. Phillip’s-head screw 18. Thermostat assembly 28. Battery terminal link
9. Lockwasher 19. Heater Unit 29. Bellville spring
10. Phillip’s-head screw 20. Heater Unit 30. Double D washer
TM 11-6140-203-14-3
Figure 2-11. Battery, Storage BB-693a/u (Manufactured by General Electric), Parts Location.
2-12
TM 11-6140-203-14-3
1. Heater Assembly 22. Binder head screw
2. cover assembly 23. Rolled washer
3. cover gasket 24. Thermostat assembly
4. Battery terminal link 25. Valve assembly
5. Battery terminal link 26. Valve assembly
6. Battery terminal link 27. Case assembly
7. Battery terminal link 28. O-ring
8. Hexaganol head screw 29. Connector receptacle, electrical J2
9. Flat washer 30. Oval head screw
10. Belleville washer 31. Countersunk tooth lockwasher
11. Cell 32. Protective cap
12. Vent cap assembly (p/o cell (11)) 33. Protective cap
13. O-ring (p/o vent cap assembly (12)) 34. Srpring
14. Splice 35. Dust cap
15. Cable assembly 36. Warning nameplate
16. Connector assembly 37. Instruction nameplate
17. Connector gasket 39. Instruction nameplate
18. Binder head screw 40. O-ring (p/o valve assembly(25))
19. Rolled washer 41. O-ring (p/o valve assembly(26))
20. Connector receptacle J3 42. Manual Vent Valve (2)
21. Connector gasket
Figure 2-11. - Continued
2-16. Weight and Dimensions of by General Electric.

BB-693A/U and BB-693/U 2-17. Characteristics of Cells in BB-693A/U
Battery, Storage BB-693A/U (NSN 6140-01-072-3123) and BB-693/U
which contains polypropylene separated cells and The cells used in the BB-693 are 913/32 inches high,
Battery BB-693/U (NSN 6140-00-862-2979) weigh 39/64 inches wide, and 125A4 inches deep. Each cell
approximately 83 pounds. The battery is 101/4 inches weighs approximately 31/2 pounds. However, there are
high, 12 inches wide, and 1P/4 inches deep. Refer to differences between the cells. Cells from different
figure 2-10 for parts location for the BB-693A/U manufacturers or which have different stock numbers
manufactured by Marathon (Sonotone) Battery must never be mixed in the same battery. The table
Corporation and figure Marathon (Sonotone) Battery below lists the various cells and stock numbers used in
Corporation and figure 2-11 for parts location for the BB- the BB-693A/U and BB-693/U.
693A/U manufactured Cell Manufacturer Cell NSN Comments
Battery Designation Marathon 6140-00-8814887 Preferred Type
BE-693A/U (NSN 6140-01-072-3123) BB-600A/A General Electric 6140401-051-9844 Preferred Type

SAFT N/A
BB-693/U (NSN 6140-00-862-2979) 18191-14 Marathon 6140-00-408-4936 UsetoExhaustion
43B034ACOSG5 General Electric 614040-408-4937
The cells used in the BB-693A/U are the longer lasting separator BB-600A/A cells. The battery should then be
polypropylene separator BB-600A/A; which is also used redesigned as a BB-693A/U battery case from either
in the BB-433A/U aircraft battery. Only these cells have Marathon or General Electric. However, all 19 cells in the
been designed to meet the BB-693A/U requirements as battery must have the same stock number and manufac-
well as those of aircraft. The older BB-600/A cell with turer. Refer to figure 2-10 for the cell layout for a
cellophane separator may not meet the BB-693A/U re- Marathon built battery or figure 2-11 for the cell layout
quirements. All 19 cellophane separator cells in a BB- for one built by General Electric.
693/U battery can be replaced with 19 polypropylene
SECTION IX. BATTERY, STORAGE BB-634/U (6TNC)
2-18. Tabulated Data for BB-634/U (6TNC) inches of mercury O0.1).
Type ................................ Nickel cadmium (vented). Storage:
Number of cells ............... 10. Duration ....................Unlimited, regardless of state of
Electrolyte Potassium hydroxide (KOM), 31 charge.
percent (by weight) in distilled Temperature.....................-650 F. (53.90 C.) to 1650 F.
water. (73.90 C.).
Operating range:.............. Atmospheric pressure.......Sea level to 50,000 feet (3.4 inch-
Temperature ............. -40 F. (-40°C.) to 125°F. es of mercury +/-0.1).
(51.7°C.). Electrical data.
Atmospheric pressure ...... Sea level to 10,000 feet (20.6 Rating .......................70 ampere-hours.
2-13
TM 11-6140-203-14-3
Current at rated load (14 am-Temperatures between 700

pere): F. (21.10 C.) and 850 F.
(29.40 C.) ..................12 volts for approximately 5
Temperatures between hours.
0°F. (-17.8°C.) and Temperatures between 0°F.
125°F. (51.7°C.) 14 ampere for approximately 5 (-17.8°C.) and -40°F.
hours. (-40°C.) ....................11.5 volts for approximately 3
hours.
Temperatures between Intercell connector (molded in
0°F. (-17.80 C.) and place):
-40'F (-40°C) 14 ampere for approximately 3 Material .....................Nickel-Plated copper.
hours. Number .....................9.
Voltage: Cell plate materials:
Open circuit .............. Approximately 13 volts (fully Positive (charged)......Nickel oxide.
charged, with a 24-hour rest Negative (charged) ....Cadmium.
period). Separator material ....Nylon cellophane sandwich.
Under rated load (14 ampere):
2-14
TM 11-6140-203-14-3
Figure 2-12. Battery, Storage BB-634/U (6TNC)
2-19. Dimensions of BB-634/U (6TNC)
The overall dimensions of the BB-634/U (6TNC) (NSN 6140-00-900-8537) are 9 inches high, 101/2 inches
wide, and 11¼ 4 inches deep. Refer to figure 2-12 for an overall view of the battery. No repair parts are
authorized for this equipment.
2-15
TM 11-6140-203-14-3
CHAPTER 3
INSTALLATION
3-1. Unpacking
a. When packed for domestic shipment, the batteries are packed several to a larger wooden case (fig. 3-
1) (each enclosed in a separate container).
b.
CAUTION
Do not attempt to pry off the wooden cover. Remove the nails for the cover and lift
off. The batteries may be damaged by the prying tool.
(1) Remove carton from wooden packing case, when applicable.

(2) Slit the gummed tape of the cardboard carton.
(3) Remove the battery from the cardboard carton. If the battery fits tightly in the
carton, hold the carton down when lifting the battery.
3-1
TM 11-6140-203-14-3
Figure 3-1. Typical Nickel-Cadmium Battery Packaging (Multiple)

3-2. Checking Unpacked Equipment
a. Inspect the equipment for damages incurred during shipment. If the equipment has been damaged, report
the damage on DD Form 6 (para 1-3b).
b. Check to see that the equipment is complete as listed on the packing slip. Report all discrepancies in
accordance with procedures given in TM 38-750. Shortages of a minor assembly or pan that does not affect
proper functioning of the equipment should not prevent use of the equipment.
3-2
TM 11-6140-203-14-3
NOTE
New batteries are prepared for service by direct support, general support, or depot maintenance
personnel only.
c. Prepare the new battery for service as given in paragraph 5-5.
3-3. Battery Service Record-Format

a. Record Format. When placing a battery in service for the first time, prepare and use the format, in
duplicate, similar to that shown in DD Form 314 (Preventive Main- tenance Schedule and Record (Card)) of TM
38-750 to provide a record of each individual battery. This record will serve as a verification of maintenance
accomplished.
b. Recording Procedure.
(1) Affix one copy of the record to the battery immediately after formation of the battery at direct
support.
(2) File the duplicate copy of the record at the direct support shop that accomplished the formation
of the battery.
(3) Entries are to be made on the copy mounted on the battery by organizational Shop personnel
as necessary.
(4) Make entries on the direct support file copy every time the battery is in direct support shop for
service.
(5) Make cross entries (direct support personnel), as necessary, to update on each file copy of the
battery record. When records are filled, start a new copy. Direct support personnel should remove old record
from battery and affix current record to battery. Direct support personnel should retain all duplicate copies in
their file.
3-4. Installation of Nonaircraft Nickel-Cadmium Battery
NOTE
Place into service only new batteries that have been prepared for service by higher category of
maintenance personnel.
Installation of the particular nonaircraft nickel-cadmium battery will differ from ground system to ground system.
For installation procedures of each different nonaircraft nickel-cadmium battery, refer to the manual covering
the ground system. In addition, observe the following:
a. Securing Battery in Position. When installing the battery in its position to power a ground system,
see that all electrical connections are made secure. Leads to the battery should be of sufficient size to carry the
maximum current. The battery should be secured by holddowns.
b. Venting of Gases. During the charging cycle, some hydrogen and oxygen gases are evolved. When
the battery is installed in a confined location, provide some means of ventilation from this confined area to
avoid accidental ignition of the hydrogen. Always charge with cover removed.
3-5. Emergency Procedures

Alkaline or nickel-cadmium batteries may experience an overheated condition resulting from internal shorting
or thermal runaway. The overheated battery presents a hazardous condition to equipment, vehicle, and
personnel. When an overheated battery is detected, turn off charging source, disconnect battery and wait for
battery to cool. Emergency personnel should open the battery compartment, check for the following conditions
and then take the action indicated.
a. If flame is present, use the available extinguishing
agent.
b. If no flame is present, but smoke, fumes or electrolyte is being emitted from the battery or vent
tubes, use water fog to lower the battery temperature.
c. If no flame or fire is present, and smoke, hydrogen/oxygen gas or electrolyte is not being emitted
from the battery or vent tubes, ventilate the battery compartment.
WARNING
C02 is an acceptable fire extinguishing agent once a fire has developed. In no case should C02 be
directed into a battery compartment to effect cooling or displace explosive gases. The static electricity
generated by the discharge of the extinguisher could explode the hydrogen/oxygen gases trapped in the
battery compartment.
d. Following the visual check and the action indicated above; emergency personnel should disconnect
and remove the battery. Additional cooling may be accomplished with water fog.
3-3
TM 11-6140-203-14-3
CHAPTER 4
ORGANIZATIONAL MAINTENANCE
4-1. Scope of Organizational Maintenance
The maintenance duties assigned to the operator's of end item which are powered by nonaircraft nickel-cadmium
batteries, and organizational maintenance personnel for nonaircraft nickel-cadmium batteries are listed below,
together with a reference to table or paragraphs covering the specific maintenance functions. Test equipment, tools,
and supplies required for the performance of organizational maintenance are listed in paragraph 4-2.
a. Operator daily preventive maintenance checks and services (at the equipment site) are limited to making
sure that the battery case, cover and the top of the cells are kept clean and free of potassium carbonate deposits Sara
4-7) and, during operation of the end item of equipment, being alert for any indications which signal battery
malfunction.
b. Organizational weekly preventive maintenance checks and services for the BB-693A/U only (see para 4-
5).
c. Organizational quarterly maintenance is limited to removal of the battery from the equipment and
returning it to higher category of maintenance for reconditioning. The battery must be returned to higher category
maintenance for reconditioning if is has been through 100 cycles (discharged through normal operation (or for any
other reason intentional or accidental) and recharged) prior to 2 the scheduled quarterly maintenance date. Do not
allow the battery to remain in operation longer than the 120-day period or 100 cycles since its storage capacity will be
greatly impaired and the duration of equipment operation severely limited.
d. Visual inspection (para 4-6).
e. Touchup painting (para 4-8).
f Electrolyte level check (para 4-9).
g. Electrical leakage test (para 4-10).
h Terminal screw torque (para 4-11).
i. Organizational repair (para 4-12).
4-2. Test Equipment, Tools, and Supplies
The following test equipment, tools, and supplies are required for organizational maintenance.
a. Test Equipment. Multimeter AN/USM-223.
b. Tools. Tool Kit, Battery Service TK-90/G.
c. Supplies. Lint-free cloth (item 1, app E).
4-3. Preventive Maintenance
Preventive maintenance is the systematic care, servicing, and inspection of nickel-cadmium batteries to prevent
occurrence of trouble, reduction of downtime, and insurance that the equipment is serviceable.
a. Systematic Care. Procedures given in paragraphs 4-6 through 4-11 cover routine systematic care and
cleaning essential to the proper upkeep of the equipment.
b. Preventive Maintenance Checks and Services. The preventive maintenance checks and services instructions. contained
in paragraph 4-la and 4-1c, and paragraph 4-5 outline functions to be performed at specific intervals. These checks
and services are to maintain nickel-cadmium batteries in a combat-serviceable condition; that is, in good general
(physical) condition and in good operating condition. To assist operator and maintenance personnel in maintaining
combat serviceability, the maintenance guidance indicates what to check, how to check, and the normal indications.
The procedure information, where applicable, lists the paragraphs or manuals that contain detailed repair or
replacement procedures. If the defect cannot be remedied by performing the corrective actions listed, a higher
category of maintenance or repair is required. Records and reports of these checks and services must be made in
accordance with requirements given in
4-4. Organizational Preventive Maintenance Checks and Services
Organizational preventive maintenance checks and services of the nickel-cadmium batteries are required daily, and
in addition to daily, quarterly (or every 100 discharge-charge cycles) whichever shall occur first.
a. Paragraph 4-la specifies checks and services that must be accomplished daily.
b. Paragraph 4-5 specifies checks and services that must be accomplished weekly for the BB-693/U only.
c. Paragraph 4-1c specifies additional checks and services that must be performed quarterly (or every 100
discharge-charge cycles) whichever shall occur first.
4-5. Weekly Preventive Maintenance Checks and Services for BB-693A/U ONLY
Perform the following preventive maintenance checks and services for the BB-693A/U only on a weekly basis.
Performance of this procedure does not exempt the battery from the required quarterly (or 100 discharge-charge
cycle) maintenance.
NOTE
Weekly Preventive Maintenance Checks and Services for BB-693A/U is only required if battery power has
been used during the previous week.
a. With the BB-693A/U mounted in the vehicle, use the APU or vehicle generator system to charge the
battery and monitor charging current until the charging current remains steady for one hour. Set charging
voltage using 1% meter to the following values at the ambient temperatures given:
(1) Above 800 F.-28V.
(2) Between 32-F.-80F.-28.5V.
(3) Below 320 F.-29V.
b. Allow the battery to rest (stand) for not less than
4-1
TM 11-6140-203-14-3
one-half hour or more than 2 hours. Remove the filler caps and check the electrolyte level following the instructions
contained in paragraph 4-9. If the electrolyte level requires adjustment refer to higher category of maintenance.
c. Perform the electrical leakage test following the instructions contained in paragraph 4-10. If the leakage cur-
rent indication is less than 30 milliamperes (ma), the battery passes the electrical leakage test. If the indication is more than
30 ma, remove the battery from the vehicle and clean it as specified in paragraph 4-7. Repeat the electrical leakage test. If
the battery still fails to pass the test, refer the problem to higher category of maintenance.
d. A battery which passes the electrical leakage test after cleaning, should be placed on charge until the charging
current is 5 amperes or less.
4-6. Visual Inspection
Many causes of battery failure may be detected by visual inspection. Because the battery cannot be disassembled by
organizational maintenance personnel, visual inspection is limited to observing the assembled battery. Visual inspection is
accomplished as follows:
a. Damage. Release the snap fasteners, remove the cover, and check the battery as indicated in (1) through (7) below.
(1) Battery case or cover scratched or dented.
(2) Battery case liners or cover gasket loose or damaged.
(3) Cell terminal or terminal screws bent or broken.
(4) Cell cases cracked.
(5) Filler cap warped or cracked.
(6) Connector bent or broken.
NOTE
If electrolyte appears on tops of cells, check setting of charging voltage, paragraph 4-5a, and perform leakage test,
paragraph 4-Sc. Proceed as directed in paragraph 4-7.
(7) Tops of cell cases and caps for presence of electrolyte.
b. Improper Installation. Check the battery for improper installation as indicated in (1) and (2) below.
(1) Filler cap improperly seated.
(2) Loose terminal screws, battery terminal links, or connector.
c. Loose Connections. Check for loose connections as listed below.
(1) Battery terminal links between cells.
(2) Battery terminal links between cells and receptacle.
d. Electrolyte Leakage. If electrolyte leakage is present in the battery and is not the result of an improperly
installed filler cap or spillage, a cell case is probably cracked check for cracked cell cases (tops). In any case of electrolyte
leakage, higher maintenance category repair is required.
e. Corrosion or Deposits. Corrosion or white potassium carbonate deposits are caused by gassing and
bubbling of electrolyte through the vent valves on the fillercaps. Check for either as follows:
(1) Check the top of the cell cases, cell terminals, battery terminal links, and fillercaps.
(2) Check the battery case and cover.
4-7. Cleaning
CAUTION
Do not attempt to clean the nickel-cadmium battery with solvents, adds or any chemical cleaner; damage
to the cells, gaskets, and the liner may result. DO NOT disassemble the battery; clean only those parts
that can be reached without disassembly.
Potassium carbonate deposits in the dry state are nonconductive and when in contact with nickel- or nickel-
plated material is noncorrosive. When moisture is added to the powder, which occurs with drastic humidity
changes, an electrical leakage path is established. Also, if the potassium carbonate comes in contact with
copper, which could occur if the nickel-plating is scratched, corrosion will set in. For these reasons, the battery
must be carefully cleaned and kept free of potassium carbonate deposits.
a. Release the snap fasteners, as necessary, and remove the cover from the battery case.
b. Brush any deposits from the cell tops and intercell connectors with a nylon brush. DO NOT use a
wire brush. Wipe off the loosened deposits.
c. Wipe the battery case with a clean lint-free cloth (use item 1, app E).
d. If electrolyte is spilled on the cells or in the battery (between the cells), clean the battery without disassembly as follows:
(1) Secure the fillercaps on the cells.
(2) Set the battery on a clean surface, remote from any contaminants.
(3) Thoroughly wash the tops of the cells with distilled water. (if distilled water is not available, use drinking water.)
(4) After washing the tops of the cells, lay the battery on its side and raise the bottom of the
battery a few inches to allow drainage of the excess water from between the cells.
WARNING
To be usable for cleaning, the compressed air source must limit the nozzle pressure to no more than 29
pounds per square inch gauge (PSIG). Goggles must be worn at all times while cleaning with
compressed air.
(5) Allow the battery to remain in this position until dry. Compressed air may be used to speed the
drying process, if available.
e. Clean the fillercaps as follows:
(1) Use the fillercap wrench to turn each fillercap one-fourth turn counterclockwise and remove
each fillercap from its cell.
4-2
TM 11-6140-203-14-3
(2) Wash each fillercap thoroughly in tap water. Completely dry each filercap with a clean, dry, lint-
free cloth and compressed air as necessary.
(3) Use the fiflercap wrench to replace each fillercap to each cell, and tighten by turning the fillercap
one-fourth turn clockwise.
f. Foreign matter should not normally collect in the fillercap seat on the cell. To remove foreign matter
from the fillercap seat; use either of the following methods:
(1) Remove the fillercap, e above. Use a clean, dry, lint-free cloth and very carefully remove any
foreign matter which has accumulated in the fillercap seat. Make certain that none of the foreign matter falls into the cell.
(2) Cut the lugs off a fillercap which is going to be thrown away. Remove the fillercap from the cell (e
above). Place a clean, dry, lint-free cloth over the base of the fillercap without lugs. Place it over the fillercap seat to
be cleaned and turn the fillercap and cloth with a fillercap wrench.
4-8. Touchup Painting Instructions

a. When the battery requires repainting, refinishing, or touchup painting, refer to Federal Standard No.
595a for a matching color. SB 11-573 lists painting tools and miscellaneous supplies required for painting.
b. Refer to TB 43-0118 for instructions on painting and preserving Electronics Command equipment.
When touchup painting, a perfect match with the original paint surface may not be possible because of a change in
the is original pigment as a result of oxidation and differences in manufacture. The prevention of corrosion and
deterioration is the most important consideration in touchup painting; appearance is secondary. However, this does
not mean that appearance of the equipment is not important. Touchup painting should be accomplished neatly and
competently. Inspection personnel in the field should make allowances for slight color mismatch where minor
touchup has been done, but not for neglect, unskillful manner, or in cases where the need for refinishing is obvious.
c. When the finish on the battery box has become badly scarred or damaged, rust and corrosion can be
pre- vented by touching up the bare surfaces. Use a very fine sandpaper to clean the surfaces down to the bare
metal. Obtain a bright smooth finish.
d. Spray one coat of zinc chromate primer (NSN 8010-00-514-1861) (item 2, app E) to the smooth finish.
When dry, apply one or two thin coats of olive drab, semi-gloss paint (NSN 8010-00-598-5936) (item 3, app E) to protect
the battery box from further corrosion.
4-9. Electrolyte Level Check

Electrolyte level check should be performed only after the battery has been fully charged and allowed to rest a minimum of
30 minutes but not more than 2 hours. If the battery has been at rest beyond the maximum limit, it must be fully recharged
and allowed to rest before at-tempting to check the electrolyte level. This is necessary because the apparent electrolyte level
drops with time after charge.
a. Remove the battery case cover.
b. Remove the battery fillercaps.
c. If the electrolyte level can be seen above the cell plates by looking into the cell fillercap openings, replace
battery fillercaps and battery case cover. If electrolyte cannot be inspected visually, proceed to d below.
d. If the electrolyte level cannot be checked visually because of the battery location, proceed as follows:
(1) Insert a clean 1/s-inch diameter, 6-inch long piece of plastic tubing or ordinary drinking straw (NSN 7350-
00-290-2887 or NSN 7530-00-271-1683) into the cell and lower it until the tubing or straw touches the baffle or the tops of the
plates. Cover the opposite end of the tubing or straw with the index finger to create a partial vacuum.
(2) Raise the tubing or straw to the cell fillercap seat. While observing the end that was inserted into the
cell, remove the finger from the other end to release the vacuum and any electrolyte that may be trapped in the tubing or
straw.
(3) If any electrolyte drips from the tubing or straw, replace the battery fillercap and go to the next cell and
perform the procedure described in (1) and (2) above.
e. If electrolyte is not found in all cells of the battery while performing the visual procedure in c above or the tubing
check in d above, remove the battery from service, install a replacement battery, and evacuate the battery to direct support
maintenance. NEVER will organizational maintenance personnel add to or remove distilled water or electrolyte from the
battery.
4-10. Electrical Leakage Test

a. Disconnect the battery for the equipment it powers at the battery receptacle.
b. Set the AN/USM-223 function switch to DC MA position.
c. Plug the black test lead into the COM jack.
d. Plug the red test lead into the 10A jack.
e. Place the red test probe of the AN/USM-223 to the positive terminal of the battery. If the battery case is metal,
place the block test probe of the AN/USM-223 to a clean, paint-free surface of the battery case such as the latches. If the
battery case is not metal, place the black test probe on internal metal support raises, latches, etc. or on a paint-free metal
surface on which the battery case is mounted.
f. If the meter pointer indicates more than 2.5 amperes, record the meter indication and proceed to l below.
g. If the meter pointer indicates less than 2.5 amperes, remove the test probes from the battery and the battery
case or metal surface. Move the red test probe from the AN/USM-223 1OA jack to the V- f -A jack place the range switch in
the 2500 position.
h. Reconnect the AN/USM-223 test probe as described in e above.
4-3
TM 11-6140-203-14-3
i. If the meter pointer does not move close to midscale, turn the range switch one range at a time,
until a midscale indication is obtained.
j. Record the meter indication.
k. Repeat the procedures described in d through j above with the black test probe of the AN/USM-223
connected to the negative terminal of the battery and the red test probe to a paint-free surface as described in e
above.
l. If any of the milliampere (ma) indications recorded in j above is greater than the ampere-hour
rating of the battery being tested, remove the battery from service and send it to direct support maintenance for
repair on a direct exchange basis. Remove the battery from service if the leakage current is more than 5.5 ma
when testing a 5.5 ampere-hour battery or more than 30 ma when testing a 30 ampere-hour battery, etc.
4-11. Terminal Screw Torque

WARNING
Be extremely careful when tightening the terminal screws. Bodily injury and equipment damage may
result if the torque wrench accidentally causes a short circuit.
The terminal screws are tightened with the aid of the torque wrench and a socket or screwdriver adapter (p/o
TK-90/G).
NOTE
For batteries that have Allen-head terminal screws, an Allen-head adapter is needed for the torque
wrench.
a. Place the socket, screwdriver adapter, or Allen-head adapter on the torque wrench.
b. Insert the torque wrench into the loose terminal screw.
c. Rotate the torque wrench clockwise until the given number, in inch pounds as listed below, is
indicated on the torque wrench.
Screw or stud diameter Inch-pounds to tighten
8-32 (screw) Between 20 and 25
10-32 (screw) Between 35 and 50
10-32 (stud) Between 15 and 20
5/16-24 (stud) Between 20 and 25
d. Carefully remove the torque wrench.
4-12. Organizational Repair

Organizational repair of nonaircraft nickel-cadmium batteries is limited to replacement of fillercaps, tightening
terminal screws, replacement of 0-ring seals, replacement of connector dust caps, and replacement of the
pressure relief valve on the BB-693/U. Instructions for each of these functions are given below:
WARNING
The storage battery is charged and will cause bodily injury and equipment damage if the cell terminals or
connectors terminals are short circuited. Be extremely careful when repairing the storage battery.
a. Removal and Replacement of Fillercaps.

WARNING
Electrolyte on the filercap will cause serious burns if allowed to come in contact with the flesh.
To remove the fillercap use the vent cap wrench. Place the vent cap wrench over the fillercap and turn
counter-clockwise one-quarter turn until loose and remove the fillercap from the cell. To replace the fillercap
turn the vent cap wrench one-quarter turn clockwise until the filtercap is tight. Remove the vent cap wrench.
b. Tightening Terminal Screws. Tighten loose terminal screws by following the directions given in
paragraph 4-11.
c. Removal and Replacement of O-Ring Seals.
(1) Remove the fillercap by following the directions given in a above.
(2) Carefully wash the fillercap to remove any trace of electrolyte before replacing the O-ring seal.
(3) Grasp the fillercap firmly with one hand.
(4) With the other hand, remove the 0-ring seal on the bayonet end of the fillercap.
(5) Replace with a new 0-ring seal by holding one side of the new seal in place and stretching the other side over
the tangs, sliding the 0-ring seal against the shoulder of the fillercap. Make certain the 0-ring seal is seated firmly.
(6) Place the fillercap on the cell by following the instructions given in a above.
d. Removal and Replacement of Connector Dust Cap (BB-422 Only).
(1) Remove the screw that holds the connector dust cap keeper chain to the battery box.
(2) Unscrew the connector dust cap from the battery connector.
(3) Place the new connector dust cap of the battery connector. Hand tighten the connector dust cap.
(4) Secure the connector dust cap by inserting the screw through the connector dust cap keeper chain and secure
it to the battery box.
e. Removal and Replacement of Pressure Relief Valve (BB-6931U Only). Remove the BB-693/U pressure relief
valve by unscrewing it from the battery case. Screw a replacement pressure relief valve into the same location.
4-4
TM 11-6140-203-14-3
CHAPTER 5
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE
5-1. General Instructions
The direct support and general support maintenance procedures given in this chapter supplement those de-
scribed for organizational maintenance (chap. 4) and consist of the following.
a. Preparing a new battery for service (para 5-5).
b. Adjusting electrolyte level (para 5-6).
c. Periodic service procedures (quarterly or every 100 discharge-charge cycles) (para 5-7).
d. Troubleshooting (para 5-8).
e. Disassembly (para 5-9).
f Reconditioning battery components (para 5-10).
g. Vent valve test (para 5-1 1).
h. New cell procedure (Para 5-12).
i. Filler vent valve test (ma 5-13).
5-2. Test Equipment, Tools, Additional Equipment and Supplies
Test equipment and tools authorized for the direct support and general support maintenance levels are listed in
the maintenance allocation chart, (app D). Expendable supplies and materials are listed in appendix E.
CAUTION
Maintenance personnel must wear a face shield (item 4, app E) or goggles (item 5) and an apron (item
6), while handling, servicing or making repairs to a battery.
5-3. Battery-Charger Equipment
The following battery charger equipment and cables are available for servicing nonaicraft nickel-cadmium batteries.
a. Charger, Battery PP-1659/G.
b. Generator set, gasoline engine (NSN 6115-00-475 0029), 3 kilowatts, 28 volts dc, MIL-G-52428
(used for battery charging where 115-volt or 230-volt ac power is not available).
c. Charger, Battery PP-1451/G.
d. Power Supply PP-1 104C/G with relay, reverse current cutoff (NSN 5945-00-824-5575).
e. Charger, Battery PP-6267 (for charging Battery, Storage BB-429/U).
f. Generator Set, Gasoline Engine PU-532/PPS-4 (for operating Radar Set AN/PPS-4 and charging
Battery, Storage BB-422/U).
g. Cable Assembly Set MX-4765/PPS-4 (for operating Radar Set AN/PPS-4 and charging Battery,
Storage BB-422/U).
h. Cable Assembly, Power Electrical CX-11935/U, (BB-501/U, BB-651/U only).
i. Charger/Analyzers such as the AN/(JSM 432, RF-80GT (Christie Electric) or AN/GSM-261 may be
used if available.
NOTE
Check Charger/Analyzer literature to determined the particular battery to be
charged can be operated on the specific charger.
5-4. Battery Rest Period After Charging
a. After the nonaircraft nickel-cadmium battery has been fully charged, it should be allowed to rest for
a minimum of 30 minutes to a maximum of 2 hours before checking the electrolyte level. If the 2-hour
maximum time is exceeded before the level of the electrolyte is checked, the battery must be brought back up
to the full charge state and allowed to rest again before performing the check.
b. The maximum rest time must be strictly adhered to. After the battery has been removed from the
battery charger, it will discharge gases trapped between the separators and plates during the rest period. At
this progresses, electrolyte solution is absorbed into the battery plates in place of the gases. It the battery has
rested longer than the maximum period of time, absorption could bring the electrolyte level to the point that
inspection would indicate than more should be added. Correction of the electrolyte level under these conditions
could overfill the cell and cause spewing when the battery is brought to a full charge while installed in the
equipment for service.
5-5. Preparing New Battery for Service
A new battery is a battery that has never been placed in use or a battery taken out of storage for use. Perform the
procedures given in a through g below to prepare a new battery for service.
a. Initial Inspection. Remove the cover and perform the following internal checks:
(1) Damage. See whether any electrolyte liquid has spilled into the battery case or shipping container. This
condition may be a sign of a damaged cell.
(2) Electrical Connections. Check all electrical connections for tightness. Test all screws on terminals to en-
sure tightness. Refer to paragraph 4-11 for correct terminal screw torque. Check any wing for proper connection. Poor
electrical contact may result in damage to the battery.
(3) Electrolyte Level The batteries are normally shipped with the proper amount of electrolyte. Do not add dis-
tilled water or electrolyte until after the battery is charged. When a battery has been discharged or allowed to stand unused
over a period of time, the electrolyte becomes absorbed into the plates. The batteries are shipped discharged and,
therefore, the electrolyte level may seem low. Charging the battery should cause this level to rise to the proper mark, which
is just above the tops (approximately one-fourth inch) of the plates. Do not charge cells of different capacities together.
Adjust if necessary in accordance with instructions in paragraph 5-6.
b. Clean Battery. Clean the battery by following the instructions contained in paragraph 4-7.
5-1
TM 11-6140-203-14-3
c. Check Polarity Position of Cells. Check the polarity position of each cell or group of cells to be sure
that they are connected properly. The polarity of each cell is indicated by a plus (+) sign molded into the cell
cover adja- cent to the appropriate cell post. For the cell layout for a specific battery, refer to the cell layout of
that specific battery (chap. 2).
d. Tighten Terminal Screws. Tighten terminal screws as described in paragraph 4-1 1.
e. Clean Fillercaps. Clean the fillercaps by following the instructions contained in paragraph 4-7e.
NOTE
Refer to paragraph 2-3, TM 11-6140-203-15-1 for detailed information concerning the electro-chemical
action when charging a nickel-cadmium battery.
WARNING
Explosive gases may be released during charging. Check to be sure that the charging area is. well
ventilated. Do not use matches or an open flame in the charging area. Guard against short circuits;
resulting arcs may cause an explosion. Do not disconnect the charging cable from the battery until the
battery charger has been turned off. Explosions or serious burns may result.
f. Charging. Charge the battery using the constant- voltage method or the constant-current charging
method as given in (1) or (2) below. At the end of charge, before
the current has been shut off, the individual cell voltages should be checked for uniformity. Cell voltages
should be within 0.1 volts of each other. Low cell voltage (under 1.2 volts) may indicate a shorted cell, while
high voltage (over 1.9 volts) indicate either a dry cell or bad connection.
(1) Constant-Voltage Method. Table 5-1 provides the constant-voltage charging rate required for
temperature, number of cells, and time to accomplish the charge cycle. For example, for a temperature of 800
F and a battery containing 19 cells, charge for 2 hours at 30 volts. Periodically monitor the constant-voltage
charging rate by placing the test prods of a voltmeter across the battery terminals and adjust the output of the
battery charger, as necessary).
(2) Constant-Current Method. Table 5-2 provides the constant-current charging value required for
the specific ampere-hour rating of a battery and the amount of time it normally takes to accomplish the charge
cycle. For example, for a fully discharged battery, charge a 34-ampere-hour battery at 21.3 amperes for 2
hours, 10.6 amperes for 4 hours, or 6.8 amperes for 7 hours. If the battery does not meet the minimum end-of-
charge voltage, check individual cells for low voltage .If no low cells are present then charge must be continued
until the minimum voltages are reached. A new battery may require 20-30% more charge than normal on its
very first charge
.
Table 5-1.Constant-Voltage Charging Rate
Table 5-2. Constant-Current Charging Rate and End- Table 5-2. Constant-Current Charging Rate and End-
of-Charge Voltage of-Charge Voltage-Continued
5-2
TM 11-6140-203-14-3
g. Performance Test. Performance testing for a new battery, before placing it into service, consists of
discharge capacity and electrical leakage tests. A battery which passes both of these tests is considered to be
serviceable.
(1) Discharge Capacity Test.
(a) After charging (f above), allow the battery to rest (para 5-4) and check the electrolyte level (para 5-5).
(b) Refer to table 5-3 for the discharge time, current rate, and variable resistor value for the battery to
be tested.
(c) Connect the switch (item 7, app E), variable resistor (item 8) and test equipment as shown in figure
5-1. Two multimeters (AN/USM-223) are required. Charger/Analyzers as indicated in 5-3i, may be used in
place of resistors. Check Charger/Analyzer literature to determine if the particular battery to be tested can be
operated on the specific Charger/Analyzer.
(d) Begin the discharge capacity test
(e) When the battery has been discharged for the specific time, at the rate indicated in table 5-3,
measure the closed circuit battery terminal voltage and then as quickly as possible, the individual cell voltage.
(f) The battery terminal voltage should be as specified in table 5-3. If any cell is less than 1 volt, stop
discharging and mark the cell(s) which measure less than 1 volt for replacement.
(g) If batteries are discharged at a higher rate then specified in table 5-3, refer to section 2 for
applicable capacity at the specific rate.
(h) If all cells are 1 volt or greater, stop discharging and recharge the battery (f above). Allow the
battery to rest and adjust the electrolyte level (para 5-6). Proceed to 2 below.
Table 5-3. 2 hour Discharge Capacity Test
Figure 5-1. Capacity test Connection Diagram
5-6. Adjusting Electrolyte Level.

CAUTION
For batteries requiring electrolyte adjustment, be sure to perform the charging
procedures given in paragraph -5-f These procedures must be followed to prevent
overfilling cells that have marginal headspace. Overfilling will cause spillage of
5-3
TM 11-6140-203-14-3
electrolyte resulting in damage to the battery. Do not adjust electrolyte level after a battery has discharged.
The correct electrolyte level cannot be determined when the battery has been discharged. Conversely, never
allow electrolyte to fall below the cell level indicators when the battery is in a charged condition. Low
electrolyte level in the charged condition will cause the cells to heat up, resulting in their destruction.
NOTE
An inherent characteristic of nickel-cadmium battery cells is that the electrolyte is absorbed within the
plates and separators to a point where it is not visible from the top of the cells when at a low state of
charge or in a discharged condition. When the battery is recharged, the electrolyte level rises and
reaches its maximum height at full charge. Ideally the electrolyte level should be checked on a fully
charged battery that has been at rest for 30 minutes. The correct level of electrolyte is 1/4 inch above
the top of the plates of a fully charged cell that has been at rest for the time specified in paragraph 5-4.
The procedure for checking the electrolyte level is exactly the opposite of that for lead-acid batteries in
which the electrolyte level is adjusted by adding water before placing the battery on charge, or whenever
the electrolyte level is low.
The maximum electrolyte level for a nickel cadmium battery is one-fourth inch above the top of the places.
Perform the following procedures for electrolyte adjustments:
a. Before using the syringe, if necessary, modify it as follows:
(1) Use a sharp pin that has been heated with a flame from a match to pierce the stem of the
syringe one-fourth inch from the bottom of the stem (A, fig. 5-2).
(2) Let the pin remain in the stem for 2 or 3 minutes and then withdraw the pin slowly from the
stem.
b. Remove the fillercaps with the nylon wrench.
CAUTION
Do not spill electrolyte on the battery. Spilled electrolyte may cause corrosion of connectors and short-
circuiting between cells, resulting in damage to the battery.
c. Use the stem-pierced syringe, filled with distilled water item 9, app E), insert the syringe into the
cell until it rests on the top of the plates (B, fig. 5-2). Slowly squeeze the contents of the bulb until the bulb is
empty or the electrolyte is just below the mouth of the cell. Avoid overfilling.
d. Release the bulb to withdraw all liquid that is one- fourth inch above the top of the plates. if no
liquid is withdrawn, repeat c above.
e. Repeat c and d above for all cells.
f. Replace the fillercaps after the electrolyte level of all cells has been adjusted.
g. Thoroughly wash out the syringe.
5-4
TM 11-6140-203-14-3
EL4EC019
Figure 5-2. Electrolyte Level Adjustment
5-7. Periodic Service Procedures

For batteries returned to direct support or general support for quarterly or every 100 discharge-charge cycles
maintenance service, proceed as follows:
a. Perform the procedures given in paragraph 5-5a through e.
NOTE
Refer to TM 11-6140-203-15-1 for information concerning the temporary loss of
capacity of a nickel-cadmium battery and the discharge method recommended to
restore the rated capacity to the nickel-cadmium battery.
b. The following discharge fixtures are available for completely discharging all the cells in
the indicated battery:
(1) Battery, Storage BB-422/U, use fixture, NSN 6110-00-179-8273.
(2) Battery, Storage BB693A/U, use fixture NSN 6110-00-014-6225.
c. Discharge the battery using the proper load fixture and the instructions contained in (4) below. If a
load fixture is not available then proceed as described in (1), (2), and (3) below.
(1) Connect the 0- to 7.5-ohm, 1.000-wan variable resistor (item 8, app E), two Multimeters
AN/USM-223, knife switch (item 7), and nickel cadmium battery to be discharged as shown in figure 5-3. (Be
sure that the knife switch is in the open position.)
(2) Close and open the knife switch as necessary while adjusting the 0- to 7.5-ohm variable
resistor for a resistance value high enough to permit the discharge current to flow at approximately the 2-hour
rate of the battery. Monitor the terminal voltage of each cell during discharge using the AN/USM-223. When
the terminal voltage of a cell reaches 0 volts, place a shorting device
5-5
TM 11-6140-203-14-3
(spring metal strip) across the positive and negative terminals of that cell. DO NOT USE ANY OTHER
METHOD TO DETERMINE WHEN A SHORTING DEVICE SHOULD BE PLACED ACROSS THE CELL
TERMNALS.
NOTE
For the BB-634/U (6TNC) the individual cell terminals are not accessible.
Therefore, discharge at the 6-hour rate until the total battery voltage reaches 10.0
volts.
(3) Disconnect the equipment from the battery.
Figure 5-3. Discharging Connection Diagram.
(4) Discharge a battery which has a discharge fixture as follows:
(a) Position the appropriate discharge fixture (5-4 for BB-422/U) over an uncovered battery. Push
down firmly on the discharge fixture unto it uniformly covers the battery case.
(b) Clamp the battery case catches on the strikes of the discharge fixture bottom plate.
(c) Leave the discharge fixture on the battery for 16 to 18 hours. After 16 to 18 hours of discharge,
remove the discharge fixture
5-6
TM 11-6140-203-14-3
Figure 5-4. Discharging battery, Storage BB-422/U, Using Discharge Fixture
c. After discharge (b above), charge the battery as follows:

(1) Charge the battery, using constant-potential or constant-current method. Refer to table 5-1 to
determine the charging voltage for the constant-potential method. Refer to table 5-2 to determine the charging
current for the constant-current method.
(2) After charging the battery, allow it to rest (para
5-7
TM 11-6140-203-14-3
5-4). Remove the fillercaps. Adjust the electrolyte level (para 5-6).
(3) Replace the fillercaps.
d. Test the performance of the battery as given in paragraph 5-5g.
5-8. Troubleshooting
The following procedures will aid in troubleshooting a defective battery. Visually inspect the battery to
determine whether the trouble is caused by loose connections (a below), corroded connections (b below),
electrical leakage (c below), or an incorrectly Installed cell (d below).
a. Loose Connections. If connections are loose,
proceed as follows:
(1) Clean the battery (para 4-7) and tighten terminal screws, using the proper torque valves (para 4-11).
(2) Discharge the storage battery (para 5-7c).
(3) Charge the battery as follows:
(a) Charge the battery, using constant-potential or constant-current method. Use table 5-1 to
determine the charging voltage for the constant-potential method. Refer to table 5-2 to determine the charging
current for the constant-current method.
(b) After charging, allow the battery to rest (para 5-4). Remove the fillercaps. Using distilled
water, adjust the electrolyte level by bringing the electrolyte level to not more than one-fourth inch above the
top of the plates (para 5-6).
(c) Replace the fillercaps.
(4) Test the performance of the battery as given in paragraph 5-5g.
b. Corroded Connections. if the cell terminals or the connector terminals are corroded, completely
disassemble and clean the battery as given in paragraph 5-9.
c. Electrical Leakage Test. Using the AN/USM-223, perform the electrical leakage test as described
in paragraph 4-10.
d. Reverse Polarity Position. If a cell has been installed in reverse polarity as determined when
performing an individual cell voltage test, proceed as follows:
(1) Discharge the battery (para 5-7c).
(2) Remove and reinstall the cell in the battery.
(3) Charge the battery (para 5-5s.6
(4) Capacity test the battery (para 5-5-g).
e. Troubleshooting Table. Table 5-5 is provided to aid in isolating troubles that occur in the battery.
Before following the procedures outlined in the troubleshooting table, perform the procedures given in a through
d above.
Table 5-5. Troubleshooting
5-9. Disassembly
A complete disassembly of the battery is required for any of the following defects: Defective cell or cells,
electrolyte leakage, electrical leakage, cell installed in reverse polarity, or defective battery case.
Disassemble the battery, as given in a through e below:
a. Discharge the battery as given in paragraph 5-7c
b. After completely discharging the battery, remove all terminal links by removing their screws and
associated washers
c. Remove all cells from the battery case as follows:
(1) Loosen all fillercaps to relieve any internal pressure.
(2) Fabricate a cell puller by using two terminal links bent at right angles and appropriate
nonconductive heavy cord or flat web material as shown in figure 5-5.
NOTE
Do not use wire or other conductive material. Use the cell terminal screws and
washers to secure the cell puller to the cell terminals and
5-8
TM 11-6140-203-14-3
carefully work each cell out of the battery case starting with the cell that is approximately in the center position.
NOTE
If a cell puller cannot be fabricated as shown in figure 5-5, screw a stud of the appropriate size into
each cell terminal. Grasp these studs with pliers and lift the cell straight up.
d. Remove liners from the battery case and inspect the interior of the case for peeling or chipping
of paint or corrosion. Return defective cases to the depot for repair.
e. Remove the battery terminal connector or receptacle as follows:
(1) Remove screws and washers that hold the connector or receptacle to the battery case.
(2) Remove the battery terminal connector or receptacle.
CAUTION
Be careful when removing the gaskets from the battery case. Do not allow the scraper to gouge the
battery case.
(3) For connectors or receptacles having damaged gaskets, remove the gaskets by scraping or
peeling the gasket from the battery case. For batteries having liners or cover gaskets, remove liners
and cover gaskets by scraping or peeling.
5-9
TM 11-6140-203-14-3
Figure 5-5. Cell Puller.

5-10. Reconditioning Battery Components
After the battery is disassembled (para 5-9), proceed as follows:
a. Individual Cell Inspection.
(1) Remove, clean (para 4-7), and replace fillercaps on all cells. Be sure fillercaps are on
tight.
CAUTION
Do not allow tapwater to enter cell; the electrolyte will be diluted or contaminated and will require replacement.
(2) Wash each cell with tapwater. Remove potassium carbonate deposits by brushing with
the nylon brush. Rewash the cell with tapwater.
5-10
TM 11-6140-203-14-3
WARNING
To be used for cleaning, the compressed air source must limit the nozzle pressure to no more than 29 pounds per square
inch gauge (PSIG). Goggles must be worn at all times while cleaning with compressed air.
(3) Air hose until dry.
(4) Lightly buff each cell terminal with fine sandpaper or emery cloth.
(5) Examine each cell for cracks, distorted case, discoloration, and electrolyte contamination. If a cell has a
crack or distorted case, the cell is beyond repair and should not be used. If the exterior of a cell is discolored with burn
spots or contains electrolyte contamination (contamination is evident if foreign substances are in electrolyte), the cell is
unserviceable and should be discarded. For cells that visually appear to be free of cracks, discoloration, distortion, and
electrolyte contamination, proceed as follows to test the cell for electrolyte leakage:
(a) Invert cell for 2 minutes.
(b) After the cell has been inverted for 2 minutes, lay cell on each of its sides either on a blotter or a
paper towel for 30 seconds per side. Any wetting of the blotter or the paper towel is cause to consider the cell repairable, if
the leakage is from the cell terminal only. This repair can be accomplished by the depot. Coordinate the shipment of
these defective cells with Commander, US Army Communications and Electronics Materiel Readiness Command, ATTN:
DRSEL-MMG-B, Fort Monmouth, NJ 07703.
b. Installing Cover Gasket.
(1) Check to be sure that the cover is clean and dry.
(2) Lay the cover on a clean, flat surface and thoroughly clean the side of the cover to be cemented.
(3) Apply a layer of cement (item 10, app E) to the cleaned area of the cover.
(4) Apply a layer of cement to the cleaned side of the cover gasket.
(5) Position the cover gasket on the cover, with the cemented areas of both cover and cover gasket mating.
(6) Firmly press (by hand) the cover gasket in place on the cover.
(7) Allow at least 2 hours for the cement to dry before installing the cover on the battery.
c. Installing Battery Terminal Connector or Receptacle.
Check to be sure that the terminal connector or receptacle is clean and dry. (2) Install the terminal connector or
receptacle, using screws, washers, and gaskets as required.
d. Installing Battery Case Liner.
NOTE
If necessary to replace any liner, use polyamnide
plastic sheet (item 11, app E).
(1) Check to see that the battery case is clean and dry.
(2) Cut the battery case liner or insulator (polyamide plastic sheet, (NSN 9330-00-877-2872)) to the same size as the
one removed and install the replacement battery case liner in the battery case.
e. Installing Cells in Battery Case.
NOTE
Each battery must be constructed of cells made by the same manufacturer and carry the
same stock number. DO NOT mix cells made by different manufacturers or different stock
numbers from the same manufacturer, to retrofit a battery. Use cells with or as close to the
same date code or length of service as possible.
(1) Replace liners. Using appropriate cell layout diagram shown in chapter 2 for the specific battery, replace
all cells in the battery case. If a cell is difficult to insert, apply a light coat of petroleum jelly or teflon spray to the sides of
the cell case and press firmly into place with the polarity symbols in the correct direction. Cells are connected in series
(positive to negative). Using polyamide plastic sheets (item 11, app E), shim cells as necessary for a tight fit.
(2) Replace all terminal hardware in the following sequence:
(a) Intercell connectors.
(b) Belleville washer.
(c) Flatwasher.
(a) Stud (finger tight).
NOTE
Torque hardware before applying corrosion preventive compound. Be sure all cell
terminals and intercell connectors are clean and smooth before assembling.
(3) Torque all connections as specified in paragraph 4-11. After reassembly, coat all hardware with
corrosion preventive compound item 12 app E).
f. Charging. Charge the battery, using constant-potential or constant-current method (para 5-f). Allow the
battery to rest (Para 5-4). Remove the fillercaps. Use distilled water to adjust the electrolyte level to one-fourth inch
above the top of the plates Sara 5-6).
g. Testing. Perform the procedures given in paragraph 5-Sg to test the battery.
5-11. Vent Valve (metal) Test
a. Fabricate the metal vent valve tester as shown in figure 5-6.
b. Install 24 metal vent valves to be tested into the 24 holes. Tighten each metal vent valve sufficiently to prevent
leakage when air pressure is applied.
c. Connect air pressure pump with a 0- to 25-pound per square inch (psi) gauge to the Shrader valve mounted on the
metal vent valve tester
d. Submerge the metal vent valves into a tank of water. Slowly apply air pressure until 2 psi is reached. Observe for
leakage. If any metal vent valves leak with the 2 psi of air pressure applied, the metal vent valve is defective and
5-11
TM 11-6140-203-14-3
should be discarded. Continue slowly increasing the applied air pressure until 10 psi of air pressure is reached.
Observe for leakage. Metal vent valves that do not leak with 10 psi of air pressure applied are defective and
should be discarded.
5-12
TM 11-6140-203-14-3
NOTE:
HOLES DRILLED AT 90 TO FACILLIATE INSTALLATION OF VENT VALUVES BY PLACING VENT
VAULVE TESTER ON EITHER SIDE. EACH SIDE ACCOMIDATES 12 VENT VALVES.
Figure 5-6. Fabrication Diagram for Metal Vent Valve Tester
5-13
TM 11-6140-203-14-3
5-12. Individual New Cells

When individual new cells are being prepared for use, be careful when charging. Do not charge individual cells
unless the plastic cell case is externally supported because gas pressure, while charging the unprotected cell,
may cause the cell case to crack. When assembling cells to make up a battery, be sure that all cells were
constructed by the same manufacturer and have the same NSN. To avoid an unbalance in the battery, do not
mix cells made by different manufacturers or having different NSN's to retrofit a battery.
5-13. Fillercap Vent Valve Test
a. Fabricate the fillercap vent valve tester as shown in figure 5-7. (Use a test cell that has been
flushed clean and is empty of electrolyte. )
b. Before testing, wash the fillercap thoroughly in detergent and water.
CAUTION
To be used for cleaning, the compressed air source must limit the nozzle pressure
to no more than 29 pounds per square inch gauge PSIG). Goggles must be worn
at all times while cleaning with compressed air.
c. After washing, rinse the fillercap with clean water and dry with an air blower.
d. Place the fillercap to be tested on the test cell.
e. Connect the air regulator to a compressed air outlet and adjust the air pressure until it builds
up in the test cell. The filercap vent valve should open between 2 psi and 10 psi.
f. if the fillercap vent valve does not open between 2 psi and 10 psi, discard the filercap. If the
filercap vent -valve does open between 2 psi and 10 psi, remove the 0- ring from the fillercap, replace with a
new 0-ring, and return the fillercap to stock for reissue.
Figure 5-7. Fabrication Diagram for Fillercap Vent Valve Tester
5-14. Battery Blanket Electrical Test
The battery blanket electrical test consists of measuring for a low resistance, through the heating element, at
the battery blanket terminal board. An infinite or very high
5-14
TM 11-6140-203-14-3
resistance indicates that the battery blanket is defective and should be replaced. As a guide the following
specifications are provided:
a. General Electric Battery Blanket
(1) Resistance. 4. 4- to 4. 8-ohms.
(2) Power Consumption. 175 watts plus or minus 9 watts at 29 volts dc.
b. Marathon (Sonotone) Battery Blanket
(1) Resistance. Center heater element, 3. 5- to 3. 6-ohms; outer heater element 8. 0- to 8. 1-

ohms.
(2) Power Consumption. Center heater element, 107 watts at 29 volts dc; outer heater element,
253 watts at 29 volts dc. Testing of the heater blankets through the connector (J3) can only be done if the
battery has been cooled below the temperature at which the control thermostats close.
5-15
TM 11-6140-203-14-3
APPENDIX A
REFERENCES
The following publications are available to maintenance personnel of nonaircraft nickel-cadmium batteries:
DA Pam 310-4 Index of Technical Manuals, Technical Bulletins, Supply Manuals
(Types 7, 8, and 9), Supply Bulletins, and Lubrication Orders.
DA Pam 310-7 US Army Index of Modification Work Orders.
SB 11-573 Painting and Preservation Supplies Available for Field Use for
Electronics Command Equipment.
TB 43-0118 Field Instructions for Painting and Preserving Electronics
Command Equipment Including Camouflage Pattern Painting
of Electrical Equipment Shelters.
TM 11-6130-236-12 Operator and Organizational Maintenance Manual; Charger,
Battery PP- 1451/G (NSN 6130-00-985-8157).
TM 11-6130-238-14 Operator's, Organizational, Direct Support, and General
Support Maintenance Manual for Charger, Battery PP-1659/G,
and PP-1659A/G (NSN 6130-00-985-8185).
TM 11-6130-246-12 Operator's and Organizational Maintenance Manual: Power Supply
PP-1104C/G (NSN 6130-00-542-6385) (With Instructions for
Use as Battery Charger).
TM 11-6140-203-15-1 Operator, Organizational, Direct Support, General Support, and
Depot Maintenance
Manual: Aircraft and Nonaircraft Nickel-Cadmium Batteries
(General).
TM 11-6140-203-14-2 Operator's, Organizational, Direct Support, and General Support
Maintenance Manual for Aircraft Nickel-Cadmium Batteries.
TM 11-6140-203-20P-3 Organizational Maintenance Repair Parts and Special Tools Lists for Nonaircraft
Nickel-Cadmium Batteries BB-422/U (NSN 6140-00-789-
2118), BB-651/UIH6(V) (NSN 6140-00-935-5265), BB-429/U
(NSN 6140-00-996-3746), BB-501/U (NSN 6140-00-134-0850),
BB-693/U (NSN 6140-00-862-2979), and BB-651/U (NSN
6140-00-037-7344).
TM 11-6140-203-34P-3 Direct Support and General Support Maintenance Repair Parts and
Special Tools Lists (Including Depot Maintenance Repair Parts
and Special Tools) for Nonaircraft
Nickel-Cadmium Batteries BB-422/U (NSN 6140-00-789-
2118), BB-651/UIH6(V) (NSN 6140-00-935-5265), BB-429/U
(NSN 6140-00-996-3746), BB-501/U (NSN 6140-00-134-0850),
BB-693/U (NSN 6140-00-862-2979), and BB-651/U (NSN
6140-00-037-7344).
TM 11-6625-654-14 Operator's, Organizational, Direct Support, and General Support
Maintenance Repair Parts and Special Tools Lists (Including
Depot Repair Parts and Special Tools) for Multimeter
AN/USM-223.
TM 38-750 The Army Maintenance Management System (TAMMS).
TM 750-244-2 Procedures for Destruction of Electronics Material to Prevent
Enemy Use Electronics Command).
A-1
TM 11-6140-203-14-3
APPENDIX D
MAINTENANCE ALLOCATION
SECTION I. INTRODUCTION
D-1. General
This appendix provides a summary of the maintenance operations for Nonaircraft Nickel-Cadmium Batteries. It authorizes
categories of maintenance for specific maintenance functions on repairable items and components and the tools and equipment
required to perform each function. This appendix may be used as an aid in planning maintenance operations.
D-2. Maintenance Function
Maintenance functions will be limited to and defined as follows:
a. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical
characteristics with established standards through examination.
b. Test. To verify serviceability and to detect incipient failure by measuring the mechanical or electrical characteristics
of an item and comparing those characteristics with prescribed standards.
c. Service. Operations required periodically to keep an item in proper operating condition, i. e. , to clean
(decontaminate), to preserve, to drain, to paint, or to replenish fuel, lubricants, hydraulic fluids, or compressed air supplies.
d. Adjust. To maintain, within prescribed limits, by brining into proper or exact position, or by setting the operating
characteristics to the specified parameters.
e. Align. To adjust specified variable elements of an item to bring about optimum or desired performance.
f. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test measuring and
diagnostic equipments used in precision measurement. Consists of comparisons of two instruments, one of which is a certified
standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared.
g. Install. The act of emplacing, seating, or fixing into position an item, part, module (component or assembly) in a
manner to allow the proper functioning of the equipment or system.
h. Replace. The act of substituting a serviceable like type part, subassembly, or module (component or assembly) for
an unserviceable counterpart.
i. Repair. The application of maintenance services (inspect, test, service, adjust, align, calibrate, replace) or other
maintenance actions (welding, grinding, riveting, straightening, facing, remachining, or resurfacing) to restore serviceability to an
item by correcting specific damage, fault, malfunction, or failure in a part, subassembly, module (component or assembly),
end item, or system.
j. Overhaul That maintenance effort (service/action) necessary to restore an item to a completely
serviceable/operational condition as prescribed by maintenance standards (. e. , DMWR) in appropriate technical
publications. Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul does not
normally return an item to like new condition.
k. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like
new condition in accordance with original manufacturing standards. Rebuild is the highest degree of materiel maintenance
applied to Army equipment. The rebuild operation includes the act of returning to zero those age measurements (hours,
miles, etc. ) considered in classifying Army equipments/components.
D-3. Column Entries
a. Column 1, Group Number. Column 1 lists group numbers, the purpose of which is to identify components,
assemblies, subassemblies, and modules with the next higher assembly.
b. Column 2, Component/Assembly. Column 2 contains the noun names of components, assemblies, sub-
assemblies, and modules for which maintenance is authorized.
c. Column 3, Maintenance Functions. Column 3 lists the functions to be performed on the item listed in column
2. When items are listed without maintenance functions, it is solely for purpose of having the group numbers in the MAC
and RPSTL coincide.
d. Column 4, Maintenance Category. Column 4 species, by the listing of a "work time" figure in the appropriate
subcolumn(s), the lowest level of maintenance authorized to perform the function listed in column 3. This figure represents
the active time required to perform that maintenance function at the indicated category of maintenance. If the number or
complexity of the tasks within the listed maintenance function vary at different maintenance categories, appropriate "work
time" figures will be shown for each category. The number of task- hours specified by the "work time" figure represents the
average time required to restore an item (assembly, subassembly, component, module, end item or system) to a
serviceable condition under typical field operating conditions. This time includes preparation time, troubleshooting time,
and quality assurance/quality control time in addition to the time required to perform the specific tasks identified for the
maintenance functions authorized in the maintenance allocation chart. Subcolumns of column 4 are as follows:
C Operator/Crew
O Organizational
D-1
TM 11-6140-203-14-3
F Direct Support
H General Support
D Depot
e. Column 5, Tools and Equipment. Column 5 specifies by code, those common tool sets (not
individual tools) and special tools, test, and support equipment required to perform the designated function.
f. Column 6, Remarks. Column 6 contains an alphabetic code which leads to the remark in section
IV, Remarks, which is pertinent to the item opposite the particular code.
D-4. Tool and Test Equipment Requirements (Sec Ill)
a. Tool or Test Equipment Reference Code. The numbers in this column coincide with the numbers
used in the tools and equipment column of the MAC. The numbers indicate the applicable tool or test
equipment for the maintenance functions
b. Maintenance Category. The codes in this column indicate the maintenance category allocated the
tool or test equipment.
c. Nomenclature. This column lists the noun name and nomenclature of the tools and test equipment
required to perform the maintenance functions.
d. National/NATO Stock Number. This column lists the National/NATO stock number of the specific
tool or test equipment.
e. Tool Number. This column lists the manufacturer's part number of the tool followed by the Federal
Supply Code for manufacturers (5-digit) in parentheses.
D-5. Remarks (Sec IV)

a. Reference Code. This code refers to the appropriate item in section HI, column 6.
b. Remarks This column provides the required explanatory information necessary to clarify items
appearing in section II
D-2
TM 11-6140-203-14-3
SECTION II MAINTENANCE ALLOCATION CHART FOR
BATTERIES, STORAGE - BB-422/U, BB-429/U, BB-501/U, BB-693/U, BB-651/U BB-2HNC, BB-672/U, BB-6TNC
(1) (2) (3) (4) (5) (6)
GROUP COMPONENT/ MAINTENANCE MAINTENANCE LEVEL TOOLS AND
NUMBER ASSEMBLY FUNCTION C O F H D EQUIPMENT REMARKS
00 BATTERY, STORAGE BB-422/U Inspect .2 4

Inspect .7 4
Test .8 1-4
Service .2 4,5,6,
8-12
Adjust .4 3
Adjust .2 4
Repair .5 4 A
Repair .5 4
Overhaul 2.0 1-11,
15-18
Rebuild 5.0 1-18
01 BATTERY, STORAGE (CELL) BB-431/U Inspect .1 4

Test .5 4
Service .1 3,4
Replace 1.1 4
Replace .5 4 A
Repair .6 4
D-3
TM 11-6140-203-14-3
(1) (2) (3) (4) (5) (6)
GROUP COMPONENT/ MAINTENANCE MAINTENANCE CATEGORY TOOLS AND
00 BATTERY, STORAGE BB-651/UIH 6(V) and Inspect .2 4

BB-651/U Inspect .7 4
Test .8 1-4'
Service .2 4,5,6,
8-12
Adjust .4 3
Adjust .2 4
Repair .5 4
Repair .5 4
Overhaul 2.0 1-11,15-18
Rebuild 5.0 1-18
01 BATTERY, STORAGE (CELL) BB-436/U Inspect .1 4

Test .5 4
Service .1 3,4
Replace 1.1 4
Replace .5 4 A
Repair .6 4
D-4
TM 11-6140-203-14-3
(1) (2) (3) (4) (5) (6)

Inspect .7 4
Test .8 1-4
Service .2 4,5,6,
8-12
Adjust .4 3
Adjust .2 4
Repair .5 4
Repair .5 4
Overhaul 2.0 1-11,
15-18
Rebuild 5.0 1-18
01 BATTERY, STORAGE (CELL) BB418/U Inspect .1 4

Test .5 4
Service .1 3,4
Replace 1.1 4
Replace .5 4 A
Repair .6 4
D-5
TM 11-6140-203-14-3
(1) (2) (3) (4) (5) (6)

Inspect .7 4
Test .8 1-4
Service .2 4,5,6,
8-12
Adjust .4 3
Adjust .2 4
Repair .5 4
Repair .5 4
Overhaul 2.0 1-11

15-18
Rebuild 5.0 1-18
01 BATTERY, STORAGE (CEI) BB-613/U Inspect .1 4

Test .5 4
Service .1 3,4
Replace 1.1 4
Replace .5 4 A
Repair .6 4
D-6
TM 11-6140-203-14-3
(1) (2) (3) (4) (5) (6)
00 BATTERY, STORAGE BB5693/U Inspect .2 4

Inspect .7 4
Test .8 1-4
Service .2 4,5,6,
8-12
Adjust .4 3
Adjust .2 4
Repair .5 4
Repair .5 4
Overhaul 2.0 1-11,
15-18
Rebuild 5.0 1-18
01 BATTERY, STORAGE (CELL) 18191-14 Inspect .1 4

or Test .5 4
43B034AC05G5 Service .1 3,4
Replace 1.1 4
Replace .5 4 A
Repair .6 4
D-7
TM 11-6140-203-14-3
(1) (2) (3) (4) (5) (6)
00 BATTERY,STORAGEBB-672/U,BB-2Hmc,BB-6TNC Inspect .2 4
Inspect .7 4
Test .8 1-4
Service .2 4,5,6,
8-12
Replace .1 4
D-8
TM 11-6140-203-14-3
SECTION III TOOL AND TEST EQUIPMENT REQUIREMENTS

FOR
TOOL OR TEST MAINTENANCE NATIONAL/NATO
EQUIPMENT CATEGORY NOMENCLATURE STOCK NUMBER
REF CODE
1 F,H,D FIXTURE, BATTERY DISCHARGE AND CELL VOLTAGE BALANCING FOR 6110-00-179-8273
BB-422/u BATTERY. (SEE NOTE 1:)
2 F,N,D BATTERY DISCHARGE PLATE AE-IDP-1582 FOR BB-651/uIN-6(V) 5830-O0-637-0937
BATTYERY. (SEE NOTE 1. )
3 O,F,H,D MULTIMETER AN/uJSM-223.
4 O,F,H,D TOOL KIT, BATTERY SERVICE TE-90/G. 5180-00— 542-5812

5 F CABLE ASSEMBLY SET, ELECTRICAL NX4765/PPS4. (FOR USE IN 6115-00-957-3709
OPERATING RADAR AN/PPs-4 AND CHARGING BATTERY STORAGE BB-422/U).
(SPECIAL PURPOSE SEE NOTE 1. )
6 F,H,D CABLE ASSEMBLY, POWER ELECTRICAL CX-11935/u (FOR CONNECTING 5995-00-404-7535

BATTERY ASSEMBLY THAT HAS A SIX PIN RECEPTACLE TO THE BATTERY
CHARGER). (GENERAL PURPOSE SEE NOTE 1. )
7 F,H,D CHARGER, BATTER PP-1451/G. (GENERAL PURPOSE SEE NOTE 1. ) (IF 6130-00-985-8157
THE PP-i451/G IS NOT Available, USE (AS AN ALTERNATE CHARGER) THE
PP-1659/U OR PP-1104(*)/G LISTED BELOW).
8 F,H,D CHARGER, BATTERY PP-1659/u. (GENERAL PURPOSE SEE NOTE 1. ) 6130-00-985-8185
9 F,H,D CHRGER, BATTERY MODEL AEM-PSF1582 (FOR CHARGING BATTERY 5835-00637-0938

BB-651/uIH-6(V)). (SPECIAL PURPOSE SEE NOTE 1. )
10 F,H,D CHARGER BATTERY PP-6267/u (FOR CHARGING BATTER!, STORAGE 5130-00-179-8333
BB-429/u). (SPECIAL PURPOSE SEE NOTE 1. )
11 F GENERATOR SET, GASOLINE ENGINE PU-532/PPS-4 (FOR OPERATING RADAR 5115-00-889-1212
SET AN/PPS-4 AND CHARGING BATTERY STORAGE BB-422/u). (SPECIAL
PURPOSE).
12 F GENERATOR SET, GASOLINE ENGINE 3KW, 28V DC MIL-G-52428 (USED 6115-00-475-0029
WHERE AC POWER IS NOT AVAILABLE).
13 F,H,D POWER SUPPLY PP-1104c/G GENERAL PURPOSE 12 & 24V GENERAL PURPOSE 5130-00-542-6385
CHARGER. (SEE NOTE 2. )
14 F,H,D RELAY, REVERSE CURRENT CUTOFF. (SEE NOTE 2). 5945-00-824--5575
15 F,H,D EALANCING UNIT, STORAGE BATTERY (USED TO DEEP DISCHARGE 6110-00-1680585
B-693/U).
16 F,H,D MULTIMETER 300M-A AND ADAPTER KIT 6625-oo-68-o585
17 F,H,D POWER SUPPLY PP-6224/u (USED TO CHARGE BB-693/u). 6130-00-133-5879

18 F,H,D CABLE ASSEMBLY, POWER ELECTRICAL (USED TO CONNECT PP-6224a/u TO
BB-693/u FOR CHARCIING OF BB-693/u). 6150-00-214-8343
NOTES:
1. Use appropriate and available, discharge fixtures,
chargers, charging cables and analyzers when servicing batteries.
2. Reverse current relay must be connected to the output

of Dower Supply PP-1104C/G to prevent battery from discharging
through the power supply in event of power failure.
D-9
TM 11-6140-203-14-3
SECTION IV. REMARKS
REFERENCE REMARKS
CODE
A REPAIR BY REPLACEMENT OF FILLERCAP O-RING SEAL AND CONNECTOR DUST CAP.
D-10
TM 11-6140-203-14-3
APPENDIX E
EXPENDABLE SUPPLIES AND MATERIALS LIST
SECTION I. INTRODUCTION
E-1. Scope
This appendix lists expendable supplies and materials you will need to operate and maintain Nonaircraft Nickel-
Cadmium Batteries. These items are authorized to you by CTA 50-970, Expendable Items (Except Medical,
Class V, Repair Parts, and Heraldic Items).
E-2. Explanation of Columns

a. Column 1-Item Number. This number is assigned to the entry in the listing and is referenced in the
narrative instructions to identify the material (e. g. , "Use cleaning compound, item 5, app. D").
b. Column 2-Level This column identifies the lowest level of maintenance that requires the listed item.
C Operator/Crew
O Organizational Maintenance
F Direct Support Maintenance

H General Support Maintenance
c Column 3-National Stock Number. This is the National stock number assigned to the item; use it to
request or requisition the item.
d. Column 4-Description. Indicates the Federal item name and, if required, a description to identify
the item. The last line for each item indicates the part number followed by the Federal Supply Code for
Manufacturer (FSCM) in parentheses, if applicable.
e. Column 5-Unit of Measure (UIM). Indicates the measure used in performing the actual
maintenance function. This measure is expressed by a two-character alphabetical abbreviation (e. g. , ea, in,
pr). If the unit of measure differs from the unit of issue, requisition the lowest unit of issue that will satisfy your
requirements.
(Next printed page is E-3)
E-1
TM 11-6140-203-14-3
SECTION II EXPENDABLE SUPPLIES AND MATERIALS LIST
(1) (2) (3) (4) (5)

ITEM LEVEL NATIONAL STOCK DESCRIPTION U/M
NO. NUMBER PART NO. AND FSCM
1 0 8305-00-267-3015 CLOTH, CHEESECLOTH, LINTLESS, CCCC440 (81348). YD

2 0 80O1-00-514-1861 PAINT-TOUCHUP, PRIMER COATING, ZINC CHRO74ATE YEL. , 30 CAN
MINUTES DRYING TIME:USE METAL, RIGID PLASTIC, AND GLASS,
FED SPEC TT-P-00600, 16 OUNCE CAN,1319 (87187).
3 0 8010-00-598-5936 PAINT-TOUCHVP, ENAMEL, SEIIGWSS, OLIVE DRAB COLOR NO. X- CAN
24087, RUST INHIBITING USE: AS A ONE OR TWO COAT PAINTING
SYSTEM OVER PROPERLY CLEANED AND TREATED METAL, FED
SPEC TT-E-485 TYPE II, PACKED IN PRESSURZED 12 OUNCE CAN,
TTE485 (81348).
4 0 4240-00-439-3450 FACESHIELD, INDUSTRIAL, 8 IN. LG, FED-L-F-0036, STYLE B, SIZE 3, L
LF 36 (81348). EA
5 0 4240-00-203-0317 GOELIES, INDUSTRIAL, CHEMICAL TYPE GGG-G-521, TYPE II,
(81348). PR
6 0 8415-00-715-0450 APRON, IMPERMEABLE, BATTERY WORKERS MILA-A 41801 (81349). EA
7 F 5930-00-224-4938 SWITCH, KNIFE, DPST, 60 AMP, 25OV, 1143J (05684). EA
8 F 5905-00-195-4496 RESISTOR, VARIABLE, 0- TO 7. 5-OHM, 1000 WATTS (FOR EA
BUILDING BATTERY LOADS).
9 F 6810-00-682-6867 DISTILLED OR DEIONIZED WATER, 243 (24774). GAL
10 F 8014-00-664-4318 ADHESVE, RUBBER BASE, GENERAL PURPOSE, PT
EC2141 (76381).
11 F 9330-00-877-2872 POLYAMIDE PLASTIC SHEET, L-P-410 (81348). EA
12 F 8030-00-903-0931 CORRSION PREVENTATIVE COMPOUND, NOX RUST No. 366 PT
(02847).
13 F 6810-00-543-4041 ELECTROLYTE (KOH), APPROXIMATELY 31 PERCENT BY WEIOHT
PREMIXED SOLUTION IN 500 CC POLYETHYLENE BOTTLE, 1. 305
0. 005 SPECIFIC GRAVITY AT 80 F. B+1
E-3
TM 11-6140-203-14-3
INDEX
Paragraph Page
Administrative Storage ........................................................................................................... 1-4 1-1
Adjusting Electrolyte Level...................................................................................................... 5-6 5-3
Battery-Charger Equipment for Direct Support and General Storage Maintenance.................. 5-3 5-1
Battery Service Record-Format .............................................................................................. 3-3 3-1
Battery Blanket Electrical Test ................................................................................................ 5-14 5-14
Charging Procedures (Direct Support and General Support) ................................................... 5-f 5-2
Checking Unpacked Equipment .............................................................................................. 3-2 3-1
Cleaning ................................................................................................................................. 4-7 4-2
Cleaning Fillercaps ................................................................................................................. 4-7c 4-2
Destruction of Army Materiel .................................................................................................. 1-5 1-1

Disassembly (Direct Support and General Support) ................................................................ 5-9 5-8
Electrical Leakage Test .......................................................................................................... 4-10 4-3
Electrolyte Level Check .......................................................................................................... 4-9 4-3
Fillercap Vent Valve Test........................................................................................................ 5-13 5-14
Forms and Records ................................................................................................................ 1-3 1-1
General Instructions for Direct Support and General Support.................................................. 5-1 5-1
Indexes of Publications........................................................................................................... 1-2 1-1

Individual Cell Inspection (Direct Support and General Support)............................................. 5-10a 5-10
Individual New Cells (Direct Support and General Support) .................................................... 5-12 5-14
Installation:
Battery Case Liner (Direct Support and General Support)................................................. 5-10d 5-11
Battery Terminal Connector or Receptacle (Direct Support or General Support)............... 5-10c 5-11
Cells in Battery Case (Direct Support and General Support) ............................................. 5-10e 5-11
Cover Gasket (Direct Support and General Support) ........................................................ 5-10b 5-11
Nonaircraft Nickel-Cadmium Batteries.............................................................................. 3-4 3-1
Organizational Preventive Maintenance Checks and Services................................................ 4-4 4-1

Organizational Repair ............................................................................................................. 4-12 4-4
Performance Test of Nickel-Cadmium Batteries (Direct Support and General Support)......................... 5-5g 5-3
Periodic Service Procedures (Direct Support and General Support)........................................ 5-7 5-5
Physical Characteristics:
Battery, Storage BB-43 1/U (Cell)..................................................................................... 2-3 2-1
Battery, Storage BB-418/U (Cell)...................................................................................... 2-6 2-3
Battery, Storage BB-634/U (6TNC)................................................................................... 2-19 2-15
Battery, Storage BB-671I/U (Cell)..................................................................................... 2-14 2-10
Preparing New Battery for Service (Direct Support and General Support)............................... 5-5 5-1
Preventive Maintenance ......................................................................................................... 4-3 4-1
Reconditioning Battery Components (Direct Support and General Support) ............................ 5-10 5-10
Record Format ....................................................................................................................... 3-3a 3-1
Recording Procedure .............................................................................................................. 3-3b 3-1
Repair (Organizational)........................................................................................................... 4-12 4-4
Rest Period After Charging ..................................................................................................... 5 -4 5-1
Scope of Organizational Preventive Maintenance................................................................... 4-1 4-1

Scope of Technical Manual..................................................................................................... 1-1 1-1
Technical Characteristics:
Battery, Storage BB422/U ................................................................................................ 2-1 2-1
Battery, Storage BB-429/U ............................................................................................... 2-4 2-2
Index-1
TM 11-6140-203-14-3
Paragraph Page
Battery, Storage BB-634/U (6TNC)................................................................................... 2-18 2-13
Batter, Storage 6TNC (MB-634/U) .................................................................................... 2-18 2-13
Test Equipment, Tools, Additional Equipment and Supplies.................................................... 5-2 5-1
Test Equipment, Tools, Additional Equipment and Supplies (Organizational).......................... 4-2 4-1
Tightening Terminal Screws ................................................................................................... 4-11 4-4
Touchup Painting lnstructions ................................................................................................. 4-8 4-3
Troubleshooting (Direct Support and General Support)........................................................... 5-8 5-8
Unpacking .............................................................................................................................. 3-1 3-1
Vent Valve Test (Direct Support and General Support) ........................................................... 5-11 5-1
Visual Inspection .................................................................................................................... 4-6 4-2
U. S. GOVERNMENT PRINTING OFFICE:-1994-300-421/82504
Index-2
By Order of the Secretary of the Army:
E. C. MEYER
General, United States Army
Chief of Staff
Official:
J. C. PENNINGTON
Major General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 12-28, Operator maintenance requirements for Direction
and Warning Systems, Alarm and DA Form 12-36A, Requirements for Aircraft and Nonaircraft Nickel Cadmium
Batteries.
THE METRIC SYSTEM AND EQUIVALENTS
PIN: 043748-000

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TM 11-6140-203-14-3

OPERATOR'S, ORGANIZATIONAL DIRECT SUPPORT,

NONAIRCRAFT NICKEL CADMIUM BATTERIES

HEADQUARTERS, DEPARTMENT OF THE ARMY

The electrolyte used in nickel-cadmium batteries contains potassium hydroxide

EXPLOSIVE GASES ARE GENERATED BY NICKEL CADMIUM BATTERIES

DO NOT MIX SULPHURIC ACID AND KOH

The electrolyte used in nickel-cadmium batteries reacts violently to the sulfuric

Nickel-cadmium battery maintenance personnel should be thoroughly trained in the

TIGHTENING TERMINAL SCREWS AND STUDS

FIRE FIGHTING SAFETY PRACTICE

CO2 is an acceptable fire extinguishing agent once a fire has developed. In no

TECHNICAL MANUAL HEADQUARTERS

OPERATOR'S, ORGANIZATIONAL, DIRECT SUPPORT, AND

You can improve this manual by recommending improvements using DA

2-1 Battery, Storage BB-422/U, Cover Removed ....................................................................... 2-0

*This manual supersedes TM 11-6140-203-15-3, 1 December 1969, including all changed

Number Title Page

3-1 Typical Nickel-Cadmium Battery Packaging (Multiples) ................................ ....................... 3-2

Figure 2-1. Battery, Storage B-422/U Cover Removed.

SECTION I. BATTERY STORAGE BB-422/U

2-1. Tabulated Data for BB-422/U (fig. 2-1)

Temperatures between 0°F.

Under rated load (2.8 amperes):

Temperatures between 0°F.

Figure 2-3. Battery, Storage BB-422/U, Cell Layout

SECTION II. BATTERY, STORAGE BB-429/U

Figure 2-4. Battery, Storage BB-429/U, Cover Removed.

2-5. Weight and Dimensions of BB-429/U

2-6. Physical Characteristics of BB-418/U (Cell)

Figure 2-5. Battery, Storage BB-429/U, Parts Location.

SECTION III. BATTERY, STORAAGE BB-501/U

2-7. Tabulated Data for BB-501/U (fig. 2-7)

Figure 2-7. Battery, Storage BB-501/U, Exploded View

2-8. Weight and Dimensions of BB-501/U

SECTION IV. BATTERY, STORAGE BB-651/U

2-9. Tabulated Data For BB-651/U (fig. 2-8) Temperatures between

Figure 2-8. Battery, Storage BB-651/U, Exploded View

2-10. Weight and Dimensions of BB-651/U

2-11. Physical Characteristics of BB-547/UMonoblock Cell

SECTION VI. BATTERY, STORAGE BB-672/U

2-12. Tabulated Data For BB-672/U Storage:

Figure 2-9. Battery, Storage BB-672/U, Cover Removed.

2-13. Weight and Dimensions

2-14. Physical Characteristics of BB-671/U (Cell)

2-15 Tabulated data for BB-693A/U charged with 24-hour rest

2-16. Weight and Dimensions of by General Electric.

BE-693A/U (NSN 6140-01-072-3123) BB-600A/A General Electric 6140401-051-9844 Preferred Type

Current at rated load (14 am-Temperatures between 700

Figure 2-12. Battery, Storage BB-634/U (6TNC)

2-19. Dimensions of BB-634/U (6TNC)

(1) Remove carton from wooden packing case, when applicable.

Figure 3-1. Typical Nickel-Cadmium Battery Packaging (Multiple)

c. Prepare the new battery for service as given in paragraph 5-5.

3-3. Battery Service Record-Format

3-5. Emergency Procedures

4-8. Touchup Painting Instructions

4-9. Electrolyte Level Check

4-10. Electrical Leakage Test

4-11. Terminal Screw Torque

4-12. Organizational Repair

a. Removal and Replacement of Fillercaps.

Table 5-3. 2 hour Discharge Capacity Test

Figure 5-1. Capacity test Connection Diagram